Dodge - Ram 3500 Hd 4wd - Workshop Manual - 2007 - 2007

Factory Workshop Manual Make Dodge Model Ram 3500 Hd 4wd Engine and year Truck L6-6.7L DSL Turbo VIN A (2007) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest for Alarm Module: > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood Alarm Module: Customer Interest Antitheft System - Goes Off When Opening The Hood NUMBER: 08-040-06 GROUP: Electrical DATE: September 06, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: Vehicle Theft Security System Alarm May Alert When Hood Is Opened OVERVIEW: This bulletin involves selectively erasing and reprogramming the Cabin Compartment Node Module (CCN) with new software. MODELS: 2007 (DR/DH/D1/DC) Ram Truck NOTE: This bulletin applies to vehicles equipped with a remote start system (sales code XBM) prior to October 10, 2006 (MDH 1010XX). SYMPTOM/CONDITION: The Vehicle Theft Security System (VTSS) may alert (flash lights and/or sound horn) if one of the following occurs: a. The customer arms the VTSS and then reaches through an open window, pulls on the hood release, and fully opens the vehicle hood. b. The customer releases the hood but not enough to open the hood ajar switch, arms the VTSS, and then fully opens the vehicle hood. c. The customer opens the hood, arms the VTSS, the vehicle communications bus goes in to "sleep mode" (may take 10 minutes), then the "LOCK" button on the key fob is depressed. The hood ajar switch is not part of the VTSS used on domestic use vehicles. The hood ajar switch is used for export vehicles equipped with the Vehicle Theft Alarm (VTA) system. DIAGNOSIS: 1. Connect the StarSCAN(R) to the vehicle. 2. Power up the StarSCAN(R) and obtain the HOME menu. 3. From the HOME menu select "ECU VIEW". 4. Select "CCN - Cabin Compartment". 5. Select "More Options". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest for Alarm Module: > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 12 6. Select "ECU Flash" 7. Read and record the software part number that is display with "Resident Flash File For Part". 8. Is the software part number 05172187AC (or later)? a. If YES >>> then STOP. This bulletin does not apply. Further diagnosis is required. b. If NO >>> then perform the Repair Procedure. NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the CCN in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash CCN" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest for Alarm Module: > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 13 13. Highlight the listed calibration. 14. Select "Update Controller". Follow on screen instructions. 15. When the CCN update is complete, select "OK". 16. Verify the part number at the top of the "Flash CCN" screen has updated to the new part number. NOTE: Due to the CCN programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alarm Module: > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood Alarm Module: All Technical Service Bulletins Antitheft System - Goes Off When Opening The Hood NUMBER: 08-040-06 GROUP: Electrical DATE: September 06, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: Vehicle Theft Security System Alarm May Alert When Hood Is Opened OVERVIEW: This bulletin involves selectively erasing and reprogramming the Cabin Compartment Node Module (CCN) with new software. MODELS: 2007 (DR/DH/D1/DC) Ram Truck NOTE: This bulletin applies to vehicles equipped with a remote start system (sales code XBM) prior to October 10, 2006 (MDH 1010XX). SYMPTOM/CONDITION: The Vehicle Theft Security System (VTSS) may alert (flash lights and/or sound horn) if one of the following occurs: a. The customer arms the VTSS and then reaches through an open window, pulls on the hood release, and fully opens the vehicle hood. b. The customer releases the hood but not enough to open the hood ajar switch, arms the VTSS, and then fully opens the vehicle hood. c. The customer opens the hood, arms the VTSS, the vehicle communications bus goes in to "sleep mode" (may take 10 minutes), then the "LOCK" button on the key fob is depressed. The hood ajar switch is not part of the VTSS used on domestic use vehicles. The hood ajar switch is used for export vehicles equipped with the Vehicle Theft Alarm (VTA) system. DIAGNOSIS: 1. Connect the StarSCAN(R) to the vehicle. 2. Power up the StarSCAN(R) and obtain the HOME menu. 3. From the HOME menu select "ECU VIEW". 4. Select "CCN - Cabin Compartment". 5. Select "More Options". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alarm Module: > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 19 6. Select "ECU Flash" 7. Read and record the software part number that is display with "Resident Flash File For Part". 8. Is the software part number 05172187AC (or later)? a. If YES >>> then STOP. This bulletin does not apply. Further diagnosis is required. b. If NO >>> then perform the Repair Procedure. NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the CCN in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash CCN" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alarm Module: > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 20 13. Highlight the listed calibration. 14. Select "Update Controller". Follow on screen instructions. 15. When the CCN update is complete, select "OK". 16. Verify the part number at the top of the "Flash CCN" screen has updated to the new part number. NOTE: Due to the CCN programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Component ID: 211 Component : MODULE-SENTRY KEY REMOTE ENTRY Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z109 20BK/GY 5 FUSED B(+) A114 18GY/RD 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT 8-Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 24 Component Location - 41 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 25 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 27 Keyless Entry Module: Diagrams Component ID: 211 Component : MODULE-SENTRY KEY REMOTE ENTRY Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z109 20BK/GY 5 FUSED B(+) A114 18GY/RD 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT 8-Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 28 Component Location - 41 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 29 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry Keyless Entry Module: Description and Operation Module-Remote Keyless Entry Description DESCRIPTION When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 Km/h(15 mph) will also cancel the panic event. Operation OPERATION Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 33 Keyless Entry Module: Description and Operation Sentry Key Remote Entry Module Description DESCRIPTION The Sentry Key REmote Entry Module (SKREEM) (1) is sometimes referred to as the Wireless Control Module (WCM). The SKREEM is the primary component of the Sentry Key Immobilizer System (SKIS). It is also the receiver for the Remote Keyless Entry (RKE) system. The SKREEM is located on the right side of the steering column, near the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM has an integral molded plastic halo-like antenna ring (4) that extends from the bottom. When the SKREEM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle (3) is located just behind the antenna ring on the bottom of the SKREEM housing. An integral molded plastic mounting tab (2) on the rear corner of the SKREEM housing has a hole in the center through which a screw passes to secure the unit to the steering column. The SKREEM is connected to the vehicle electrical system through a single take out and connector of the instrument panel wire harness. Two SKREEM modules are used: one for vehicles equipped with RKE only, and one for vehicles equipped with RKE and SKIS. The SKREEM cannot be adjusted or repaired. If ineffective or damaged, the entire SKREEM unit must be replaced. Operation OPERATION The Sentry Key REmote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver. The SKREEM communicates over the Controller Area Network (CAN) data bus with the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), the Powertrain Control Module (PCM)/Engine Control Module (ECM) or the diagnostic scan tool. The SKREEM and the PCM/ECM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS) disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKREEM or the PCM/ECM. However, the use of this strategy also means that replacement of either the SKREEM or the PCM/ECM units will require a system initialization procedure to restore system operation. The SKREEM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM. For added system security, each SKREEM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM or ECM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM. Therefore, the Secret Key code is a common element that is found in every component of the SKIS. Another security code called a PIN, is used to gain access to the SKREEM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKREEM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM or ECM during SKIS initialization. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 34 In the event that a SKREEM replacement is required, the Secret Key code can be transferred to the new SKREEM from the PCM or ECM using a diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the ON position, the SKREEM transmits an RF signal to excite the transponder in the ignition key. The SKREEM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM sends an electronic valid key message to the PCM/ECM over the CAN bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the SKREEM sends an invalid key message to the PCM/ECM. The PCM/ECM will enable or disable engine operation based upon the status of the SKREEM messages. It is important to note that the default condition in the PCM or ECM is an invalid key; therefore, if no message is received from the SKREEM by the PCM or ECM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM also sends security indicator request messages to the EMIC over the CAN data bus to tell the EMIC how to operate the security indicator. The security indicator request message from the SKREEM tells the EMIC to turn the indicator ON for about three seconds each time the ignition switch is turned to the ON position as a bulb test. After completion of the bulb test, the SKREEM sends security indicator request messages to the EMIC to turn the indicator OFF, turn the indicator ON, or to flash the indicator ON and OFF. If the security indicator flashes or stays ON solid after the bulb test, it signifies a SKIS fault. If the SKREEM detects a system malfunction or the SKIS has become ineffective, the security indicator will stay ON solid. If the SKREEM detects an invalid key or if a key transponder-related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM will also send messages to the EMIC to flash the security indicator whenever the Customer Learn programming mode is being utilized. The SKIS performs a self-test each time the ignition switch is turned to the ON position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM memory if a system malfunction is detected. The hard wired circuits of the SKREEM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SKREEM or the electronic controls or communication between other modules and devices that provide some features of the SKIS. The most reliable, efficient, and accurate means to diagnose the SKREEM or the electronic controls and communication related to SKREEM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Page 35 Keyless Entry Module: Testing and Inspection REMOTE KEYLESS ENTRY MODULE The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Removal Keyless Entry Module: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, push inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 38 8. Disconnect the wire harness connector (2) from the Sentry Key REmote Entry Module (SKREEM) (1). 9. Remove the screw (3) that secures the SKREEM (1) to the steering column (2). 10. Disengage the antenna ring from around the ignition lock cylinder housing and remove the SKREEM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 39 Keyless Entry Module: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the Sentry Key REmote Entry Module (SKREEM) (1) onto the steering column (2) with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw (3) that secures the SKREEM to the steering column housing. Tighten the screw to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the SKREEM (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 40 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). 10. Reconnect the battery negative cable. NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS) if the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations Voice Activation Module: Locations Component ID: 206 Component : MODULE-HANDS FREE Connector: Name : MODULE-HANDS FREE Color : DK. GRAY # of pins : 22 Pin Description Circuit 1 FUSED B(+) A114 18GY/RD 2-3-4 CAN B BUS (-) D54 20WT 5 MICROPHONE 2 IN (+) X722 20LB/DG 6-7-- 8 LEFT AUDIO OUTPUT X716 20GY/TN 9 RIGHT AUDIO OUTPUT X776 20TN/GY 10 COMMON AUDIO OUTPUT X795 20DG 11 - 12 - 13 - 14 CAN B BUS (+) D55 20WT/OR 15 VOICE RECOGNITION/PHONE SWITCH SIGNAL X730 20GY/YL 16 MICROPHONE 1 IN (+) X712 20DG/LB 17 MICROPHONE IN (-) X792 20LB/DG 18 - 19 - 20 MICROPHONE FEED X793 20DG/YL 21 SENSOR GROUND X835 20OR/GY 22 GROUND Z970 18BK Component Location - 46 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 44 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 45 Voice Activation Module: Diagrams Component ID: 206 Component : MODULE-HANDS FREE Connector: Name : MODULE-HANDS FREE Color : DK. GRAY # of pins : 22 Pin Description Circuit 1 FUSED B(+) A114 18GY/RD 2-3-4 CAN B BUS (-) D54 20WT 5 MICROPHONE 2 IN (+) X722 20LB/DG 6-7-- 8 LEFT AUDIO OUTPUT X716 20GY/TN 9 RIGHT AUDIO OUTPUT X776 20TN/GY 10 COMMON AUDIO OUTPUT X795 20DG 11 - 12 - 13 - 14 CAN B BUS (+) D55 20WT/OR 15 VOICE RECOGNITION/PHONE SWITCH SIGNAL X730 20GY/YL 16 MICROPHONE 1 IN (+) X712 20DG/LB 17 MICROPHONE IN (-) X792 20LB/DG 18 - 19 - 20 MICROPHONE FEED X793 20DG/YL 21 SENSOR GROUND X835 20OR/GY 22 GROUND Z970 18BK Component Location - 46 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 46 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Description and Operation Winch Relay: Description and Operation DESCRIPTION RELAY PACK Electrical operation of the control assembly consists of four heavy duty relays, a thermal-switch located on the motor armature brush holder and a Low Voltage Interrupt (LVI) located in the control assembly. The thermal-switch interrupts the power-in function and the LVI affects both the power-in and power-out functions and must be reset by allowing the charging circuit voltage to rise above 10 volts for more than 30 seconds. The thermal switch is reset only by allowing the winch motor to cool adequately (about 30 minutes). Relay number 1 and 3 control current flow through the field windings and relay number 2 and 4 supply current to the motor armature. Operation In the power-out mode, relay number 2 and 3 are energized by the remote control switch. Current flows from the positive battery terminal through relay number 3 then through the black motor cable to the number 2 and number 1 field windings. From the black motor cable current then flows through solenoid number 2 to the motor armature to ground. In power-in mode, relay number 1 and 4 are energized. Current again flows from the battery positive cable, but this time current flows through solenoid number 1 then through field winding number 1. Current flowing in the reverse direction through the field windings cause the motor to turn in the opposite direction. From the red motor cable current then flows through relay number 4 to the black cable going to the motor armature to ground. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay Winch Relay: Service and Repair Relay Removal REMOVAL 1. Remove the relay pack (1). 2. Remove the nuts (2 & 3), disconnect the cables and remove the bus straps (4). NOTE: Relay #4 shown, all others similar. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay > Page 52 3. Remove the nuts (1) and disconnect the control wires (2). 4. Slide the relay (1) out of the retaining tab (2) and remove. Installation INSTALLATION NOTE: Relay #4 shown, all others similar. 1. Slide the relay (1) into the retaining tab (2). 2. Install the control wires (2) and install the nuts (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay > Page 53 3. Tighten the nuts to 3 Nm (25 in. lbs.). 4. Install the bus straps (4) and connect the cables. 5. Install the nuts (2 & 3) and tighten to 9.5 Nm (85 in. lbs.). 6. Install the relay pack (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay > Page 54 Winch Relay: Service and Repair Relay Pack Removal REMOVAL 1. Disconnect and isolate battery negative cable (3). 2. Remove the winch assembly (2). 3. Remove the nut and disconnect the red battery positive cable (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay > Page 55 NOTE: Relay #4 shown, all others similar. 4. Remove the control wire nuts (1) and disconnect the control wires (2) from each relay. Installation INSTALLATION NOTE: Relay #4 shown, all others similar. 1. Install the control wires (2) to all the relays and install the nuts (1). 2. Tighten the nuts to 3 Nm (25 in. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay > Page 56 3. Install the red battery positive cable (1) and install the switch wire. 4. Install the nut and tighten to 10 Nm (85 in. lbs.). 5. Install the relay pack cover (1) and install the three screws (2). 6. Install the winch assembly (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay > Page 57 7. Connect the battery negative cable (3) and verify winch operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Component ID: 211 Component : MODULE-SENTRY KEY REMOTE ENTRY Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z109 20BK/GY 5 FUSED B(+) A114 18GY/RD 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT 8-Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 62 Component Location - 41 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 63 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 64 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 65 Keyless Entry Module: Diagrams Component ID: 211 Component : MODULE-SENTRY KEY REMOTE ENTRY Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z109 20BK/GY 5 FUSED B(+) A114 18GY/RD 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT 8-Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 66 Component Location - 41 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 67 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 68 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry Keyless Entry Module: Description and Operation Module-Remote Keyless Entry Description DESCRIPTION When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 Km/h(15 mph) will also cancel the panic event. Operation OPERATION Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 71 Keyless Entry Module: Description and Operation Sentry Key Remote Entry Module Description DESCRIPTION The Sentry Key REmote Entry Module (SKREEM) (1) is sometimes referred to as the Wireless Control Module (WCM). The SKREEM is the primary component of the Sentry Key Immobilizer System (SKIS). It is also the receiver for the Remote Keyless Entry (RKE) system. The SKREEM is located on the right side of the steering column, near the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM has an integral molded plastic halo-like antenna ring (4) that extends from the bottom. When the SKREEM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle (3) is located just behind the antenna ring on the bottom of the SKREEM housing. An integral molded plastic mounting tab (2) on the rear corner of the SKREEM housing has a hole in the center through which a screw passes to secure the unit to the steering column. The SKREEM is connected to the vehicle electrical system through a single take out and connector of the instrument panel wire harness. Two SKREEM modules are used: one for vehicles equipped with RKE only, and one for vehicles equipped with RKE and SKIS. The SKREEM cannot be adjusted or repaired. If ineffective or damaged, the entire SKREEM unit must be replaced. Operation OPERATION The Sentry Key REmote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver. The SKREEM communicates over the Controller Area Network (CAN) data bus with the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), the Powertrain Control Module (PCM)/Engine Control Module (ECM) or the diagnostic scan tool. The SKREEM and the PCM/ECM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS) disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKREEM or the PCM/ECM. However, the use of this strategy also means that replacement of either the SKREEM or the PCM/ECM units will require a system initialization procedure to restore system operation. The SKREEM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM. For added system security, each SKREEM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM or ECM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM. Therefore, the Secret Key code is a common element that is found in every component of the SKIS. Another security code called a PIN, is used to gain access to the SKREEM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKREEM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM or ECM during SKIS initialization. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 72 In the event that a SKREEM replacement is required, the Secret Key code can be transferred to the new SKREEM from the PCM or ECM using a diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the ON position, the SKREEM transmits an RF signal to excite the transponder in the ignition key. The SKREEM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM sends an electronic valid key message to the PCM/ECM over the CAN bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the SKREEM sends an invalid key message to the PCM/ECM. The PCM/ECM will enable or disable engine operation based upon the status of the SKREEM messages. It is important to note that the default condition in the PCM or ECM is an invalid key; therefore, if no message is received from the SKREEM by the PCM or ECM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM also sends security indicator request messages to the EMIC over the CAN data bus to tell the EMIC how to operate the security indicator. The security indicator request message from the SKREEM tells the EMIC to turn the indicator ON for about three seconds each time the ignition switch is turned to the ON position as a bulb test. After completion of the bulb test, the SKREEM sends security indicator request messages to the EMIC to turn the indicator OFF, turn the indicator ON, or to flash the indicator ON and OFF. If the security indicator flashes or stays ON solid after the bulb test, it signifies a SKIS fault. If the SKREEM detects a system malfunction or the SKIS has become ineffective, the security indicator will stay ON solid. If the SKREEM detects an invalid key or if a key transponder-related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM will also send messages to the EMIC to flash the security indicator whenever the Customer Learn programming mode is being utilized. The SKIS performs a self-test each time the ignition switch is turned to the ON position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM memory if a system malfunction is detected. The hard wired circuits of the SKREEM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SKREEM or the electronic controls or communication between other modules and devices that provide some features of the SKIS. The most reliable, efficient, and accurate means to diagnose the SKREEM or the electronic controls and communication related to SKREEM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Page 73 Keyless Entry Module: Testing and Inspection REMOTE KEYLESS ENTRY MODULE The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Removal Keyless Entry Module: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, push inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 76 8. Disconnect the wire harness connector (2) from the Sentry Key REmote Entry Module (SKREEM) (1). 9. Remove the screw (3) that secures the SKREEM (1) to the steering column (2). 10. Disengage the antenna ring from around the ignition lock cylinder housing and remove the SKREEM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 77 Keyless Entry Module: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the Sentry Key REmote Entry Module (SKREEM) (1) onto the steering column (2) with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw (3) that secures the SKREEM to the steering column housing. Tighten the screw to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the SKREEM (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 78 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). 10. Reconnect the battery negative cable. NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS) if the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Description Seat Heater Control Module: Description and Operation Description DESCRIPTION Momentary contact push button switch/modules mounted in the instrument panel center bezel operate the heated seat system. Each heated seat switch/module has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected level (Low or High) of the seat heater. Pressing the switch/module button initiates heat. Heat remains on until switched off or until the ignition is turned off. If switched off by the ignition, a switch/module button must be pressed to restart heating. The switch/modules contain the solid state electronic control and diagnostic logic circuitry for the heated seat system. If any of the heated seat elements are inoperative or damaged one or more of the LED lamps in the switch/module for the effected seat will flash. The LED indicator lamps in each heated seat switch/module cannot be repaired. If the LED lamps are faulty or damaged, or the switch/module is inoperative or damaged the individual heated seat switch/module assembly must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Description > Page 83 Seat Heater Control Module: Description and Operation Operation OPERATION A Heated Seat Switch/Module is used to control the heated seat system. The heated seat switch/modules receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The switch/module responds to heated seat switch/module button input and ignition switch status inputs by controlling the 12v output to the front seat heating elements through integral solid-state relays. When either of the heated seat switch/module buttons are depressed the heating element for the selected seat is energized. Amber Light Emitting Diodes (LEDS) on the side of each switch/module indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. Pressing the switch/module button once will select high-level heating. Pressing the button a second time will select low-level heating. Pressing the button a third time will shut the heating elements off. The heated seat switch/module energizes an integral solid-state relay, which supplies battery current to the heating elements. When high-temperature heating is selected, the heaters provide a boosted heat level during the first four minutes of operation after heating is activated. The heat output then drops to the normal high-temperature level. If high-level heating is selected, the control system will automatically switch to the low level after two hours of continuous operation. At that time, the number of illuminated LEDs changes from two to one, indicating the change. Operation on the low setting will continue indefinitely until the switch/module button is pushed to turn the system off. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Removal Seat Heater Control Module: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. 3. Disconnect the switch/module electrical connectors. 4. Using an appropriate flat bladed tool, remove the heated seat switch/module from the bezel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Removal > Page 86 Seat Heater Control Module: Service and Repair Installation INSTALLATION 1. Align the tabs of the switch/module to the instrument panel center bezel and gently push together until the tabs are securely in place. 2. Connect the switch/module electrical connectors. 3. Install the instrument panel center bezel. 4. Connect the battery negative cable. 5. Verify heated seat system operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Component ID: 199 Component : MODULE-ANTI-LOCK BRAKES Connector: Name : MODULE-ANTI-LOCK BRAKES Color : # of pins : 46 Qualifier : (AWAL) Pin Description Circuit 1-2 FUSED B(+) A111 16DG/RD 3 CAN C BUS (+) D65 20WT/LG 4-5-6 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT 7-8-9-10 - 11 - 12 LEFT FRONT WHEEL SPEED SENSOR (+) B9 20DG/LG 13 LEFT FRONT WHEEL SPEED SENSOR (-) B8 20DG/TN 14 - 15 - 16 GROUND Z107 16BK/DG 17 - 18 CAN C BUS (-) D64 20WT/LB 19 - 20 - 21 - 22 - 23 - 24 - 25 - 26 RIGHT FRONT WHEEL SPEED SENSOR (+) B7 20DG/VT 27 RIGHT FRONT WHEEL SPEED SENSOR (-) B6 20DG/WT 28 - 29 - 30 - 31 FUSED B(+) A107 12TN/RD 32 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 33 - 34 - - Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 91 35 - 36 - 37 - 38 - 39 - 40 - 41 REAR WHEEL SPEED SENSOR (-) B22 20DG/YL 42 REAR WHEEL SPEED SENSOR (+) B222 20DG/WT 43 - 44 - 45 GROUND Z127 12BK/DG 46 - Component Location - 32 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 92 Connector: Name : MODULE-ANTI-LOCK BRAKES Color : BLACK # of pins : 14 Qualifier : (RWAL) Pin Description Circuit 1 REAR WHEEL SPEED SENSOR (+) B222 18DG/WT 2 CAN C BUS (+) D65 18WT/LG 3 CAN C BUS (-) D64 18WT/LB 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 93 5 LEFT FRONT WHEEL SPEED SENSOR (+) B9 18DG/LG 6 GROUND Z107 16BK/DG 7 FUSED B(+) A111 16DG/RD 8 REAR WHEEL SPEED SENSOR (-) B22 18DG/YL 9 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 10 LEFT FRONT WHEEL SPEED SENSOR (-) B8 18DG/TN 11 - 12 - 13 - 14 - Component Location - 32 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 94 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 95 Electronic Brake Control Module: Diagrams Component ID: 199 Component : MODULE-ANTI-LOCK BRAKES Connector: Name : MODULE-ANTI-LOCK BRAKES Color : # of pins : 46 Qualifier : (AWAL) Pin Description Circuit 1-2 FUSED B(+) A111 16DG/RD 3 CAN C BUS (+) D65 20WT/LG 4-5-6 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT 7-8-9-10 - 11 - 12 LEFT FRONT WHEEL SPEED SENSOR (+) B9 20DG/LG 13 LEFT FRONT WHEEL SPEED SENSOR (-) B8 20DG/TN 14 - 15 - 16 GROUND Z107 16BK/DG 17 - 18 CAN C BUS (-) D64 20WT/LB 19 - 20 - 21 - 22 - 23 - 24 - 25 - 26 RIGHT FRONT WHEEL SPEED SENSOR (+) B7 20DG/VT 27 RIGHT FRONT WHEEL SPEED SENSOR (-) B6 20DG/WT 28 - 29 - 30 - 31 FUSED B(+) A107 12TN/RD 32 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 33 - 34 - - Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 96 35 - 36 - 37 - 38 - 39 - 40 - 41 REAR WHEEL SPEED SENSOR (-) B22 20DG/YL 42 REAR WHEEL SPEED SENSOR (+) B222 20DG/WT 43 - 44 - 45 GROUND Z127 12BK/DG 46 - Component Location - 32 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 97 Connector: Name : MODULE-ANTI-LOCK BRAKES Color : BLACK # of pins : 14 Qualifier : (RWAL) Pin Description Circuit 1 REAR WHEEL SPEED SENSOR (+) B222 18DG/WT 2 CAN C BUS (+) D65 18WT/LG 3 CAN C BUS (-) D64 18WT/LB 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 98 5 LEFT FRONT WHEEL SPEED SENSOR (+) B9 18DG/LG 6 GROUND Z107 16BK/DG 7 FUSED B(+) A111 16DG/RD 8 REAR WHEEL SPEED SENSOR (-) B22 18DG/YL 9 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 10 LEFT FRONT WHEEL SPEED SENSOR (-) B8 18DG/TN 11 - 12 - 13 - 14 - Component Location - 32 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 99 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Description Electronic Brake Control Module: Description and Operation Description DESCRIPTION The Antilock Brake Module (ABM) (2) is mounted to the Hydraulic Control Unit (HCU) (3) and operates the ABS system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Description > Page 102 Electronic Brake Control Module: Description and Operation Operation OPERATION The ABM voltage source is through the ignition switch in the RUN position. The ABM contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in a diagnostic program memory and are accessible with the scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. NOTE: If the ABM is being replaced with a new ABM is must be reprogrammed with the use of a scan tool. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal Electronic Brake Control Module: Service and Repair Removal REMOVAL 1. Remove the negative battery cable from the battery. 2. Pull up on the ABM harness connector release and remove connector. 3. Remove the ABM mounting bolts . 4. Remove the pump connector from the ABM. 5. Remove the ABM from the HCU . Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal > Page 105 Electronic Brake Control Module: Service and Repair Installation INSTALLATION NOTE: If the ABM is being replaced with a new ABM is must be reprogrammed with the use of a scan tool. 1. Install ABM to the HCU. 2. Install the pump connector to the ABM. 3. Install mounting bolts. Tighten to 2 Nm (16 in. lbs.). 4. Install the wiring harness connector to the ABM and push down on the release to secure the connector. 5. Install negative battery cable to the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations Trailer Brake Control Module: Locations Component ID: 201 Component : MODULE-BRAKE PROVISION Connector: Name : MODULE-BRAKE PROVISION Color : BLUE # of pins : 4 Pin Description Circuit 1 GROUND Z998 18BK 2 BRAKE LAMP SWITCH OUTPUT L50 18WT/TN 3 TRAILER TOW BRAKE B(+) B40 14DG 4 FUSED B(+) A400 14TN/RD Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations > Page 109 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations > Page 110 Trailer Brake Control Module: Diagrams Component ID: 201 Component : MODULE-BRAKE PROVISION Connector: Name : MODULE-BRAKE PROVISION Color : BLUE # of pins : 4 Pin Description Circuit 1 GROUND Z998 18BK 2 BRAKE LAMP SWITCH OUTPUT L50 18WT/TN 3 TRAILER TOW BRAKE B(+) B40 14DG 4 FUSED B(+) A400 14TN/RD Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations > Page 111 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations Radiator Cooling Fan Control Module: Locations Component ID: 80 Component : DRIVE-FAN-RADIATOR Connector: Name : DRIVE-FAN-RADIATOR Color : DK. GRAY # of pins : 6 Qualifier : (DIESEL) Gender : FEMALE Pin Description Circuit 1 PWM FAN COIL SIGNAL K160 18BR/OR Pin Description Circuit 1 SENSOR GROUND K971 18BR/PK 2 FAN SPEED SENSOR SIGNAL N210 18DB/DG 2 SENSOR GROUND K916 18BR/OR 3 FAN SPEED SENSOR GROUND K161 18BR/LB 3 FAN SPEED SENSOR SIGNAL N27 18DB/GY 4-5 5 VOLT SUPPLY K668 18BR 5 5 VOLT SUPPLY F855 18PK/YL 6 FUSED B(+) A212 18PK/YL 6 FAN SPEED SENSOR GROUND K161 18BR/LB Component Location - 37 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 116 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 117 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 118 Radiator Cooling Fan Control Module: Diagrams Component ID: 80 Component : DRIVE-FAN-RADIATOR Connector: Name : DRIVE-FAN-RADIATOR Color : DK. GRAY # of pins : 6 Qualifier : (DIESEL) Gender : FEMALE Pin Description Circuit 1 PWM FAN COIL SIGNAL K160 18BR/OR Pin Description Circuit 1 SENSOR GROUND K971 18BR/PK 2 FAN SPEED SENSOR SIGNAL N210 18DB/DG 2 SENSOR GROUND K916 18BR/OR 3 FAN SPEED SENSOR GROUND K161 18BR/LB 3 FAN SPEED SENSOR SIGNAL N27 18DB/GY 4-5 5 VOLT SUPPLY K668 18BR 5 5 VOLT SUPPLY F855 18PK/YL 6 FUSED B(+) A212 18PK/YL 6 FAN SPEED SENSOR GROUND K161 18BR/LB Component Location - 37 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 119 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 120 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Dodge Ram Trucks from 2006 to 2009, do not use a horn relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 125 Horn Relay: Description and Operation Dodge Ram Trucks from 2006 to 2009, do not use a horn relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Dodge Ram Trucks, 2006-2009 all, do not use a parking lamp relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 129 Parking Lamp Relay: Description and Operation Dodge Ram Trucks, 2006-2009 all, do not use a parking lamp relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Dodge Ram Trucks, 2006-2009 all,Trailer Tow lamp relay is not serviceable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 133 Trailer Lighting Relay: Diagrams Dodge Ram Trucks, 2006-2009 all, do not use a trailer tow relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Power Distribution Module: Customer Interest Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 143 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 144 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 145 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 146 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: Customer Interest Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 151 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 152 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 153 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 154 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Power Distribution Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 160 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 161 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 162 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 163 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: All Technical Service Bulletins Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 168 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 169 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 170 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 171 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead Power Distribution Module: Locations Module-Electronic Overhead Component ID: 202 Component : MODULE-ELECTRONIC OVERHEAD Connector: Name : MODULE-ELECTRONIC OVERHEAD Color : BLACK # of pins : 6 Qualifier : (EXCEPT BASE) Pin Description Circuit 1-2 FUSED B(+) A114 18GY/RD 3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT 5 GROUND Z13 20BK/WT 6-- Component Location - 53 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 174 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 175 Power Distribution Module: Locations Module-Totally Integrated Power Component ID: 213 Component : MODULE-TOTALLY INTEGRATED POWER Connector: Name : MODULE-TOTALLY INTEGRATED POWER C1 Color : LT. GRAY # of pins : 14 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 2 TRS T41 SIGNAL (P/N) T41 18YL/DB 2 TRS T41 SIGNAL (P/N) T41 20YL/DB 2 STARTER SOLENOID CONTROL T752 20DG/OR 3-4 FUEL PUMP CONTROL K31 20BR 5 WIPER PARK SWITCH SENSE W7 20BR/GY 6-7-8 WASHER FLUID SWITCH RETURN G932 20VT/TN 9 WASHER FLUID SWITCH SENSE W1 20BR/TN 10 TRANSMISSION CONTROL T515 20YL/DB 11 HOOD AJAR SWITCH SENSE G70 20VT/LB 12 - 13 - 14 - Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 176 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 177 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C10 Color : LT. GRAY # of pins : 22 Pin Description Circuit 1 ASD CONTROL OUTPUT K342 16BR/WT 2 FUSED B(+) A405 18RD/DB 3 FUSED B(+) A941 18RD 4-5 FUSED B(+) A104 20YL/RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 178 6 FUSED B(+) A310 16RD/LB 7 REAR WINDOW DEFOGGER CONTROL OUTPUT C15 14DB/WT 8 FUSED IGNITION SWITCH OUTPUT (RUN-START) F12 14PK/RD 9 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 10 - 11 HORN CONTROL OUTPUT X22 18GY/LB 12 WIPER LOW SPEED CONTROL OUTPUT W3 18BR/WT 13 GROUND Z971 18BK 14 HEATED MIRROR CONTROL OUTPUT C16 18DB/GY 15 FUSED B(+) A212 20RD/OR 16 - - 17 FUSED B(+) A121 14RD/YL 18 FUEL PUMP CONTROL OUTPUT A109 16OR/RD 19 HORN CONTROL OUTPUT X21 18GY/YL 20 GROUND Z953 20BK 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 FUSED B(+) A400 14TN/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 179 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C2 Color : BLACK # of pins : 13 Pin Description Circuit 1-2 WASHER PUMP MOTOR CONTROL W10 20BR 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 ADJUSTABLE PEDALS OUTPUT A72 20RD/OR 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 180 6-7-8-9 FRONT AXLE LOCK CONTROL G304 20VT/DB 10 A/C CLUTCH CONTROL C13 20LB 10 A/C CLUTCH CONTROL C13 20LB/OR 11 ASD CONTROL K51 20BR/WT 12 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/OR 13 GROUND Z117 20BK/WT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 181 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C3 Color : BLACK # of pins : 22 Pin Description Circuit 1 FUSED B(+) A209 10RD 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F984 18PK/YL 4-5 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F983 20PK/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 182 6 FUSED B(+) A205 18RD/OR 7-8 FUSED B(+) A944 20RD 9 FUSED B(+) A116 16YL/RD 10 FUSED B(+) A118 18RD/OR 11 - 12 FUSED B(+) A918 20RD 12 FUSED B(+) A918 16RD 13 FUSED IGNITION SWITCH OUTPUT (RUN) F921 20PK/LB 14 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 15 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 16 FUSED B(+) A930 16RD 17 FUSED IGNITION SWITCH OUTPUT (RUN-START) F942 10PK/LG 18 TRAILER TOW LEFT TURN RELAY OUTPUTL673 18YL 19 TRAILER TOW RIGHT TURN RELAY OUTPUT L674 18LG 20 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 21 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 22 FUSED IGNITION SWITCH OUTPUT (RUN-START) F12 14PK/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 183 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C4 Color : LT. GRAY # of pins : 13 Pin Description Circuit 1 GROUND Z118 16BK/YL 2 SHIFT MOTOR CONTROL A T102 16YL 3 SHIFT MOTOR CONTROL B T101 16DG 4-5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 184 6-7-8 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 9 5 VOLT SUPPLY T103 20YL/OR 10 MODE SENSOR A D201 20WT/DG 11 SENSOR RETURN G180 20VT/YL 12 FUSED B(+) A880 20DB/RD 13 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 185 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C5 Color : BLACK # of pins : 10 Pin Description Circuit 1 LEFT FRONT TURN LAMP DRIVER L61 20WT/LG 2 RIGHT FRONT TURN LAMP DRIVER L60 20WT/TN 3 RIGHT HIGH BEAM DRIVER L34 20WT/GY 4 LEFT LOW BEAM DRIVER L43 20WT/DB 5 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 186 6-7-8 AAT SIGNAL G31 20VT/LG 9 AAT RETURN G930 20VT/TN 10 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 187 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C6 Color : BROWN # of pins : 16 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/LG 2 DIAGNOSTIC CAN C (+) D52 20WT/LB 3 CAN B BUS (+) D55 20WT/OR 4 LEFT REAR TURN LAMP DRIVER L63 20WT/DG 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 188 6 RIGHT REAR TURN LAMP DRIVER L62 20WT/YL 7 BRAKE LAMP SWITCH OUTPUT L50 20WT/TN 8-9 CAN C BUS (-) D64 20WT/LB 10 DIAGNOSTIC CAN C (-) D51 20WT/BR 11 CAN B BUS (-) D54 20WT 12 - 13 - 14 - 15 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 16 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 189 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C7 Color : BLUE # of pins : 14 Pin Description Circuit 1-2-3 RIGHT LOW BEAM DRIVER L44 20WT/TN 4 LEFT HIGH BEAM DRIVER L33 20WT/LG 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 190 6-7 A/C PRESSURE 5 VOLT SUPPLY C818 20LB/OR 8 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY 9-10 - 11 - 12 A/C PRESSURE SIGNAL C18 20LB/BR 13 A/C PRESSURE GROUND C918 20BK/LB 14 IGNITION START T751 20YL Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 191 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C8 Color : LT. GRAY # of pins : 12 Pin Description Circuit 1-2 FUSED B(+) A919 20RD 3 FUSED B(+) A106 20LB/RD 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 5 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20PK/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 192 6 FUSED B(+) A100 14RD/VT 7 FUSED B(+) A210 12OR/RD 8 FUSED B(+) A940 18RD 9 FUSED B(+) A103 18GY/RD 10 FOG LAMP CONTROL OUTPUT L89 18WT/YL 11 BACKUP LAMP FEED L1 18WT/LG 12 FUEL HEATER CONTROL OUTPUT A961 14RD 12 CONDENSER FAN CONTROL OUTPUT C123 12LB/WT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 193 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C9 Color : BLACK # of pins : 12 Pin Description Circuit 1 FUSED B(+) A111 16DG/RD 2 STARTER MOTOR CONTROL OUTPUT T750 14YL/GY 3 A/C CLUTCH CONTROL OUTPUT C3 20DB/YL 4 WIPER MOTOR HIGH SPEED FEED W4 16BR/OR 5 FUSED B(+) A114 18GY/RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 194 6 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 10PK/YL 7-8 FUSED PARK LAMP FEED L7 20WT/YL 9 FUSED PARK LAMP FEED L678 18BR 10 FUSED PARK LAMP FEED L70 20WT/GY 11 - 12 FUSED B(+) A107 12TN/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 195 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (DIESEL) Pin Description Circuit 1 B(+) A0 6RD Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 196 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 197 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (GAS) Pin Description Circuit 1 B(+) A11 8LB Pin Description Circuit 1 B(+) A0 6RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 198 Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 199 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 200 Power Distribution Module: Locations Auxiliary PDC Box Component ID: 22 Component : AUXILIARY PDC BOX Connector: Name : AUXILIARY PDC BOX Color : # of pins : 10 Qualifier : (UPFITTER PACKAGE) Pin Description Circuit 1 FUSED B(+) A420 10RD 2 3 FUSED B(+) A420 10RD 4 FUSED B(+) A422 14RD 5 FUSED B(+) A420 10RD 6 FUSED B(+) A423 14PK 7 8 FUSED IGNITION SWITCH OUTPUT (RUN) F922 16PK/RD 9 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 10 GROUND Z912 20BK Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 201 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead Power Distribution Module: Diagrams Module-Electronic Overhead Component ID: 202 Component : MODULE-ELECTRONIC OVERHEAD Connector: Name : MODULE-ELECTRONIC OVERHEAD Color : BLACK # of pins : 6 Qualifier : (EXCEPT BASE) Pin Description Circuit 1-2 FUSED B(+) A114 18GY/RD 3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT 5 GROUND Z13 20BK/WT 6-- Component Location - 53 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 204 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 205 Power Distribution Module: Diagrams Module-Totally Integrated Power Component ID: 213 Component : MODULE-TOTALLY INTEGRATED POWER Connector: Name : MODULE-TOTALLY INTEGRATED POWER C1 Color : LT. GRAY # of pins : 14 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 2 TRS T41 SIGNAL (P/N) T41 18YL/DB 2 TRS T41 SIGNAL (P/N) T41 20YL/DB 2 STARTER SOLENOID CONTROL T752 20DG/OR 3-4 FUEL PUMP CONTROL K31 20BR 5 WIPER PARK SWITCH SENSE W7 20BR/GY 6-7-8 WASHER FLUID SWITCH RETURN G932 20VT/TN 9 WASHER FLUID SWITCH SENSE W1 20BR/TN 10 TRANSMISSION CONTROL T515 20YL/DB 11 HOOD AJAR SWITCH SENSE G70 20VT/LB 12 - 13 - 14 - Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 206 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 207 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C10 Color : LT. GRAY # of pins : 22 Pin Description Circuit 1 ASD CONTROL OUTPUT K342 16BR/WT 2 FUSED B(+) A405 18RD/DB 3 FUSED B(+) A941 18RD 4-5 FUSED B(+) A104 20YL/RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 208 6 FUSED B(+) A310 16RD/LB 7 REAR WINDOW DEFOGGER CONTROL OUTPUT C15 14DB/WT 8 FUSED IGNITION SWITCH OUTPUT (RUN-START) F12 14PK/RD 9 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 10 - 11 HORN CONTROL OUTPUT X22 18GY/LB 12 WIPER LOW SPEED CONTROL OUTPUT W3 18BR/WT 13 GROUND Z971 18BK 14 HEATED MIRROR CONTROL OUTPUT C16 18DB/GY 15 FUSED B(+) A212 20RD/OR 16 - - 17 FUSED B(+) A121 14RD/YL 18 FUEL PUMP CONTROL OUTPUT A109 16OR/RD 19 HORN CONTROL OUTPUT X21 18GY/YL 20 GROUND Z953 20BK 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 FUSED B(+) A400 14TN/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 209 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C2 Color : BLACK # of pins : 13 Pin Description Circuit 1-2 WASHER PUMP MOTOR CONTROL W10 20BR 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 ADJUSTABLE PEDALS OUTPUT A72 20RD/OR 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 210 6-7-8-9 FRONT AXLE LOCK CONTROL G304 20VT/DB 10 A/C CLUTCH CONTROL C13 20LB 10 A/C CLUTCH CONTROL C13 20LB/OR 11 ASD CONTROL K51 20BR/WT 12 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/OR 13 GROUND Z117 20BK/WT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 211 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C3 Color : BLACK # of pins : 22 Pin Description Circuit 1 FUSED B(+) A209 10RD 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F984 18PK/YL 4-5 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F983 20PK/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 212 6 FUSED B(+) A205 18RD/OR 7-8 FUSED B(+) A944 20RD 9 FUSED B(+) A116 16YL/RD 10 FUSED B(+) A118 18RD/OR 11 - 12 FUSED B(+) A918 20RD 12 FUSED B(+) A918 16RD 13 FUSED IGNITION SWITCH OUTPUT (RUN) F921 20PK/LB 14 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 15 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 16 FUSED B(+) A930 16RD 17 FUSED IGNITION SWITCH OUTPUT (RUN-START) F942 10PK/LG 18 TRAILER TOW LEFT TURN RELAY OUTPUTL673 18YL 19 TRAILER TOW RIGHT TURN RELAY OUTPUT L674 18LG 20 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 21 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 22 FUSED IGNITION SWITCH OUTPUT (RUN-START) F12 14PK/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 213 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C4 Color : LT. GRAY # of pins : 13 Pin Description Circuit 1 GROUND Z118 16BK/YL 2 SHIFT MOTOR CONTROL A T102 16YL 3 SHIFT MOTOR CONTROL B T101 16DG 4-5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 214 6-7-8 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 9 5 VOLT SUPPLY T103 20YL/OR 10 MODE SENSOR A D201 20WT/DG 11 SENSOR RETURN G180 20VT/YL 12 FUSED B(+) A880 20DB/RD 13 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 215 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C5 Color : BLACK # of pins : 10 Pin Description Circuit 1 LEFT FRONT TURN LAMP DRIVER L61 20WT/LG 2 RIGHT FRONT TURN LAMP DRIVER L60 20WT/TN 3 RIGHT HIGH BEAM DRIVER L34 20WT/GY 4 LEFT LOW BEAM DRIVER L43 20WT/DB 5 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 216 6-7-8 AAT SIGNAL G31 20VT/LG 9 AAT RETURN G930 20VT/TN 10 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 217 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C6 Color : BROWN # of pins : 16 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/LG 2 DIAGNOSTIC CAN C (+) D52 20WT/LB 3 CAN B BUS (+) D55 20WT/OR 4 LEFT REAR TURN LAMP DRIVER L63 20WT/DG 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 218 6 RIGHT REAR TURN LAMP DRIVER L62 20WT/YL 7 BRAKE LAMP SWITCH OUTPUT L50 20WT/TN 8-9 CAN C BUS (-) D64 20WT/LB 10 DIAGNOSTIC CAN C (-) D51 20WT/BR 11 CAN B BUS (-) D54 20WT 12 - 13 - 14 - 15 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 16 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 219 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C7 Color : BLUE # of pins : 14 Pin Description Circuit 1-2-3 RIGHT LOW BEAM DRIVER L44 20WT/TN 4 LEFT HIGH BEAM DRIVER L33 20WT/LG 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 220 6-7 A/C PRESSURE 5 VOLT SUPPLY C818 20LB/OR 8 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY 9-10 - 11 - 12 A/C PRESSURE SIGNAL C18 20LB/BR 13 A/C PRESSURE GROUND C918 20BK/LB 14 IGNITION START T751 20YL Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 221 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C8 Color : LT. GRAY # of pins : 12 Pin Description Circuit 1-2 FUSED B(+) A919 20RD 3 FUSED B(+) A106 20LB/RD 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 5 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20PK/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 222 6 FUSED B(+) A100 14RD/VT 7 FUSED B(+) A210 12OR/RD 8 FUSED B(+) A940 18RD 9 FUSED B(+) A103 18GY/RD 10 FOG LAMP CONTROL OUTPUT L89 18WT/YL 11 BACKUP LAMP FEED L1 18WT/LG 12 FUEL HEATER CONTROL OUTPUT A961 14RD 12 CONDENSER FAN CONTROL OUTPUT C123 12LB/WT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 223 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C9 Color : BLACK # of pins : 12 Pin Description Circuit 1 FUSED B(+) A111 16DG/RD 2 STARTER MOTOR CONTROL OUTPUT T750 14YL/GY 3 A/C CLUTCH CONTROL OUTPUT C3 20DB/YL 4 WIPER MOTOR HIGH SPEED FEED W4 16BR/OR 5 FUSED B(+) A114 18GY/RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 224 6 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 10PK/YL 7-8 FUSED PARK LAMP FEED L7 20WT/YL 9 FUSED PARK LAMP FEED L678 18BR 10 FUSED PARK LAMP FEED L70 20WT/GY 11 - 12 FUSED B(+) A107 12TN/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 225 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (DIESEL) Pin Description Circuit 1 B(+) A0 6RD Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 226 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 227 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (GAS) Pin Description Circuit 1 B(+) A11 8LB Pin Description Circuit 1 B(+) A0 6RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 228 Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 229 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 230 Power Distribution Module: Diagrams Auxiliary PDC Box Component ID: 22 Component : AUXILIARY PDC BOX Connector: Name : AUXILIARY PDC BOX Color : # of pins : 10 Qualifier : (UPFITTER PACKAGE) Pin Description Circuit 1 FUSED B(+) A420 10RD 2 3 FUSED B(+) A420 10RD 4 FUSED B(+) A422 14RD 5 FUSED B(+) A420 10RD 6 FUSED B(+) A423 14PK 7 8 FUSED IGNITION SWITCH OUTPUT (RUN) F922 16PK/RD 9 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 10 GROUND Z912 20BK Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 231 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Description Power Distribution Module: Description and Operation Description DESCRIPTION The Totally Integrated Power Module (2)(TIPM) is a combination unit that performs the functions of the Power Distribution Center (PDC) and the Front Control Module. The TIPM is a printed circuit board based module that contains fuses, internal relays and a microprocessor that performs the functions previously executed by the FCM. The TIPM (2) is located in the engine compartment, next to the battery (1) and connects directly to the B+ cable (5) via a stud located on top of the unit. The ground connection is via electrical connectors. The TIPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic TIPM housing includes a base and cover. The TIPM cover is easily opened or removed for service and has a fuse and relay layout map integral to the inside surface of the cover. The TIPM housing base and cover are secured in place via mounting tabs. The mounting tabs secure the TIPM (2) to the battery tray mounting bracket (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Description > Page 234 Power Distribution Module: Description and Operation Operation OPERATION All of the current from the battery and the generator output enters the Totally Integrated Power Module (TIPM) via a stud on the top of the module. The TIPM cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal Power Distribution Module: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the B+ terminal nut (6) from the Totally Integrated Power Module (2)(TIPM) B+ terminal. Remove the B+ cable (5) from the TIPM (2). 3. Using a suitable flat blade tool, disengage the TIPM (2) upper retaining tabs from the battery tray bracket (3). 4. Grasp the TIPM (1) and rotate the assembly up to free it from its mounting bracket (3). Position the assembly upside down to access the electrical connectors located on the bottom of the unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal > Page 237 5. Disconnect the electrical connectors (2) by depressing the locking tab and rotating the connector arm outboard, until the connector is free from the TIPM assembly (1). Be certain to pull the connectors straight off. 6. Remove the TIPM (1) from the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal > Page 238 Power Distribution Module: Service and Repair Installation INSTALLATION 1. Position the Totally Integrated Power Module (1)(TIPM) into the vehicle. NOTE: Totally Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors (2) by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the TIPM assembly (1). 3. Turn the TIPM (1) so that the connector side is facing down. Install the assembly onto the TIPM battery tray bracket (3) making sure to line up the lower retaining tab with the retaining slot in the tray (1). 4. Push the TIPM (1) downward to lock the upper retaining clips into the bracket (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal > Page 239 5. Install the B+ terminal cable (5) and nut (6) on the B+ terminal of the TIPM (2). 6. Connect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) Relay Box: Locations Fuses (Integrated Power Module) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) > Page 244 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) > Page 245 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) > Page 246 Relay Box: Locations Auxiliary PDC Box (Upfitter Package) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) Relay Box: Application and ID Fuses (Integrated Power Module) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 249 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 250 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 251 Relay Box: Application and ID Auxiliary PDC Box (Upfitter Package) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 258 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 259 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 260 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 261 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 262 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 263 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 264 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 265 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 266 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 267 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 268 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 269 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 270 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 271 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 272 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 273 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 274 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 275 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness Technical Service Bulletin # K01 Date: 100510 Recall - ECM Update For OBD Readiness May 2010 Dealer Service Instructions for: California Emissions Recall K01 Reprogram ECM OBD Readiness Effective immediately all repairs on involved vehicles are to be performed according to this notification. Service Bulletin 18-038-09 is no longer applicable for the involved vehicles only. Models 2003 (DR) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETC) and a California emission control system (sales code NAE). 2006-2007 (DH/D1) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETH) and a California emission control system (sales code NAE). 2007 (DC) Dodge Ram Truck (3500 series cab chassis) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ) and a California emission control system (sales code NAE) built through January 5, 2007 (MDH010508). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process or GRS DealerCONNECT functions. Subject The Engine Control Module (ECM) on about 25,208 of the above vehicles may fail to accurately report diagnostic system information with some generic scan tools. This may cause the vehicle to be rejected or fail an Inspection/Maintenance Test (also known as a Smog Check). Repair The Engine Control Module (ECM) must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Part Number Description 04275086AB Authorized Modifications Label Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 284 The special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the label plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 285 To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: The DRBIII(R) must be used to perform this recall on 2003 Model Year (MY) vehicles. The 2003 MY procedure is found in Section D of the Service Procedure. Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall on 2006-2007 MY vehicles. This procedure must be performed with software release level 10.03 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 286 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's" button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section E. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 287 h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section E. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 288 e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 10. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 9. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 10. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 11. Continue with Section E. Install Authorized Modification Label. D. Reprogram the ECM Using DRBIII(R): The DealerCONNECT System, DRBIII(R) (Diagnostic Readout Box scan tool), CH7000A flash cable and CH7035B data cable are required to perform this repair. Do not attempt to perform the flash procedure using an outdated CH7000/CH7001 flash cable. NOTE: Whenever a controller is reprogrammed, the software in the DRBIII scan tool must be programmed with the latest revision level available. NOTE: If the flash process is interrupted or aborted, the flash should be restarted and then follow the directions on the DRBIII scan tool. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 289 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the DRBIII CH7000A flash cable from the DRBIII scan tool to the data link connector located inside the vehicle under the steering column. 3. Connect the CH7035B data cable from the DealerCONNECT machine to the MDS port on the DRBIII scan tool. 4. Place the vehicle's ignition key in the "RUN" position. 5. From the DealerCONNECT "WELCOME" screen, enter your "User I.D.," "Password" and "Dealer Code". 6. From the DealerCONNECT "HOME PAGE" select the "SERVICE" tab. 7. From the "SERVICE" tab screen select "TechTOOLS". 8. If the DRBIII scan tool does not "Auto Connect" select # 2 on the DRBIII key pad "Connect to TechCONNECT". 9. After the "Auto Connect" process is complete, select "READ PART NUMBER(S) FROM VEHICLE" on the TechCONNECT screen. 10. Continue following the TechCONNECT on-screen instructions. 11. Select the applicable update calibration. 12. Select the "DRBIII" button located at the bottom of the TechCONNECT monitor screen. 13. Select the "DOWNLOAD / UPDATE" button located next to the "DRBIII" button. NOTE: The system software will automatically download to the DRBIII scan tool. 14. After the software download to the DRBIII scan tool is complete, close the "DOWNLOAD / UPDATE PROGRESS" window. 15. Disconnect the DRBIII scan tool from the TechCONNECT CH7035B data cable. 16. Select # 1 "RETURN TO NORMAL MODE" on the DRBIII scan tool. 17. Use the following procedure to download the flash from the DRBIII scan tool to the vehicle. a. Select # 7 "VEHICLE FLASH" on the DRBIII scan tool. b. Follow the directions displayed on the DRBIII scan tool screen. c. After the reprogramming is complete, record the new module part number displayed on the DRBIII scan tool screen. d. Press the "PAGE BACK" button on the DRBIII scan tool. 18. Due to the ECM flash procedure, Diagnostic Trouble Codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS, ORC) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules, record the trouble codes, and erase the trouble codes using the following procedure: a. Turn the vehicle's ignition key to the "RUN" position. b. From the DRBIII scan tool Main Menu select # 1 "DRBIII Stand-Alone". c. From the DRBIII scan tool Stand-Alone menu select # 3 "Vehicle Module Scan". d. From the DRBIII scan tool Vehicle Module Scan menu select # 1 "1998 - 2005 Module Scan". e. Select "YES" on the DRBIII scan tool key pad to scan for DTC's. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 290 f. Follow the instructions on the DRBIII scan tool screen. g. Once the scanning process is complete, the DRBIII scan tool will display a list of all the modules. Modules on the list that have an asterisk next to them have DTC's that need to be cleared. h. Select the module that needs to have the DTC's cleared and follow the instructions on the DRBIII scan tool screen to clear the DTC's. i. Turn the vehicle's ignition key to the "OFF" position. NOTE: Erase any DTC's in the ECM only after all other modules have had their DTC's erased. 19. Disconnect the DRBIII scan tool from the vehicle. 20. Turn off the battery charger and disconnect it from the vehicle. 21. Continue with Section E. Install Authorized Modification Label. E. Install the Authorized Modifications Label: 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 291 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 296 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 297 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 298 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 299 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 300 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 301 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 302 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-003-10 > Sep > 10 > Engine Controls - ECM Update for Fan Clutch Operation Engine Control Module: Customer Interest Engine Controls - ECM Update for Fan Clutch Operation NUMBER: 07-003-10 GROUP: Cooling DATE: September 09, 2010 SUBJECT: High Coolant Temperatures On Vehicles Equipped With Snow Plows OVERVIEW: This bulletin provides information on how to program the Engine Control Module (ECM) to force the fan clutch to fully engage at all operating conditions MODELS: 2007 - 2010 DC/DM Ram 3500/4500/5500 Cab Chassis Trucks 2011 DD/DP Ram 3500/4500/5500 Cab Chassis Trucks NOTE: This bulletin applies to vehicles equipped with the 6.7L Cummins Diesel engine (Sales Code ETJ) DISCUSSION: Customers that operate their vehicle with a snowplow attached to the vehicle may cause the airflow passing through the radiator to be disrupted resulting in higher than normal engine temperatures The 6~7L Cummins ECM is equipped with software that can fully engage the fan clutch to allow an increase of airflow through the radiator Customers can initiate the fan clutch operation by performing the following button sequence NOTE: 2007 early 2009 models were not originally equipped with the fan clutch software however, recently released software does include this enhancement Ensure that the ECM software is at the latest level and if not, flash the ECM Refer to Service Bulletin 18-020-10 for additional information 1. Turn the ignition key to the run position or start the truck 2. Simultaneously press and release the Cruise Control "Cancel" button/lever and the "Exhaust Brake" button. Repeat this sequence four times within five seconds. The chime will sound twice as an audible indicator that the function is engaged 3. To disable the function, repeat the same procedure The chime will sound four times as an audible indicator that the function is disengaged NOTE: Customer's should be made aware that an increase in fan noise and a decrease in fuel economy may result when using this feature. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements Engine Control Module: Customer Interest Engine Controls - Engine Systems/Exhaust Enhancements NUMBER: 18-020-10 GROUP: Vehicle Performance DATE: June 10, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-06, DATED DECEMBER 05, 2006 AND 18-001-09, DATED JANUARY 21, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. Either wiTECH OR StarMOBILE DESKTOP CLIENT can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. StarMOBILE® SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. SUBJECT: FLASH: Engine Systems And Exhaust Aftertreatment Systems Enhancements OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement based on customer use and mileage accumulation. This bulletin involves: ^ Selectively erasing and reprogramming the Engine Control Module (PCM), 2007 - 2010 MY. ^ Selectively erasing and reprogramming the Cab Compartment Node (CCN), 2007 & 2008 MY. ^ If CCN is updated; provide a Customer Information Sheet explaining the overhead display messages. ^ One of several software changes allows for "Net Zero" and "Net Reduction" which will cause noticeable changes in idle speeds. Customers should be informed of these changes. They are explained in DISCUSSION, Improvements that address erroneous MIL illumination for DTC P0106, P0191, P2262 and P2299 DTC's, (spelled out in DISCUSSION below). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. MODELS: 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) 2008 - 2010 (DM) Ram Truck (4500/5500 Cab Chassis) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). NOTE: For some 2007 MY vehicles, the ECM flash is addressed in Recall K01, Dated May, 2010. Where applicable. please use the Recall to update the ECM and this bulletin to update the CCN software. DISCUSSION: Cab chassis trucks equipped with a 6.7L Cummins diesel have a number of software improvements available. This latest Service Bulletin (SB) will include improvements to prevent erroneous Malfunction Indicator Lamp (MIL) illumination: ^ P000F - Fuel System Over Pressure Relief Valve Activated Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 312 ^ P0087 - Fuel Rail Pressure Too Low ^ P0106 - Manifold Absolute Pressure Sensor Performance ^ P0191 - Fuel Rail Pressure Sensor Circuit Performance ^ P1011 - Fuel Pump Delivery Pressure Too Low ^ P2299 - Brake Pedal Position / Accelerator Pedal Position Incompatible ^ P2262 - Turbocharger Boost Pressure Not Detected - Mechanical Other updates will include the following operational and diagnostic improvements: 1. Stationary DeSoot is now available with this software. This feature works similar to pick up truck (DH/D1) models. 2. New DTC added for P2563 - Turbocharger Boost Control Position Sensor Performance. This DTC indicates diminished variable geometry turbocharger travel, which is resolved by replacing the turbocharger. Diagnosis and repair procedures for the DTC have been published in DTC-Based Diagnostics in TechConnect. 3. The latest PCM software includes a new extended idle feature to accommodate the extended idle times present in some duty cycles. This feature may help to reduce the accumulation of soot in the exhaust aftertreatment system when the engine is idling for an extended period of time. Briefly how this feature works: a. As needed, the engine enters an idling mode which dramatically reduces the rate of soot accumulation in the diesel particulate filter (called "Net Zero"). Further, under extended idle periods of 5 minutes or longer, the engine enters a mode which reduces the amount of soot accumulated in the diesel particulate filter (called "Net Reduction"). While in these modes, the idle speed increases to 900 RPM for a period of time. The idle speed may return to normal idle speed and then return to 900 RPM to repeat this cycle during very long idle periods. b. These modes occur automatically depending on the need to regenerate the DPF as long as the vehicle is not driven over 20 MPH or operated at high load. If the vehicle is driven over 20 MPH normal mobile desoot will occur automatically. 4. New scan tool driven fuel system diagnostic tests (same as previously released in the pick up) now available for cab chassis. DIAGNOSIS: 1. Using the scan tool, determine current software level of the PCM and CCN. Record on the repair order, for later use, the current PCM and CCN software level part numbers. Proceed to the next step. 2. Compare the current PCM software level part number with software available in the scantool. Determine if the current PCM software level part number, recorded in Step # 1, is programmable to a higher level. 3. Is the part number of the current PCM level software (recorded in Step # 1) at the latest level listed in the scan tool? a. If YES >> then the PCM DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. b. If NO >> then the PCM DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. 4. Is the vehicle a 2007 OR 2008 MY? a. Yes >>> Proceed to Step # 5. b. No >>> 2009 MY proceed to the REPAIR PROCEDURE as required. 5. Determine if the current CCN module level software part number, that was recorded earlier in Step # 1, is one of the following (or with a higher suffix): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 313 a. 05172187AH (or higher) = 2007 DC (3500). b. 05172334AG (or higher) = 2008 DC (3500) / DM (3500/4500). c. 2009 & 2010 MY vehicles came equipped with proper CCN software. 6. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 5? a. If YES >>> then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. b. If NO >>> then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. PARTS REQUIRED: REPAIR PROCEDURE; ECM MODULE REPROGRAM: NOTE: The wiTECH diagnostic application is the preferred method for flashing ECU's. Help using the wiTECH diagnostic application for flashing an ECU is available by selecting "Help" then "Help Contents" at the top of the wiTECH diagnostic application window. NOTE: The wiTECH software level must be at release 10.04 or higher to perform this procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. If required, as determined in DIAGNOSIS, above: reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > 8E - Electronic Control Modules >MODULE, Engine Control, Diesel > Service Information > Standard Procedure > PCM/ECM Programming - DIESEL. After PCM reprogramming, the following must be performed: a. Clear any DIG's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 3. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. 4. If required, as determined in DIAGNOSIS, above: reprogram the CCN using one of the following procedures, (based on scan tool use). 5. Was it determined in DIAGNOSIS, Step # 6 above, the CCN required updating? a. Yes >>> Proceed to appropriate CCN Module Reprogram Procedure Below, based on the scantool used. b. No >>> Repair is complete. NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 314 NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. CCN MODULE REPROGRAM - USING wiTECH(R): 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id and "Password", then select "OK". 6. Select the "Next tab at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash" screen follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF position", remove the wiPOD(R) and battery charger from the vehicle. StarMOBILE(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident" flash file for statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 315 b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step Se, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number (displayed at the end of the "Resident flash file for statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 316 Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "Exhaust Filter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required - See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test Engine Control Module: Customer Interest Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 321 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set Engine Control Module: Customer Interest Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 326 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 327 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: Customer Interest Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 332 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 333 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 334 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 335 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 07-003-10 > Sep > 10 > Engine Controls - ECM Update for Fan Clutch Operation Engine Control Module: All Technical Service Bulletins Engine Controls - ECM Update for Fan Clutch Operation NUMBER: 07-003-10 GROUP: Cooling DATE: September 09, 2010 SUBJECT: High Coolant Temperatures On Vehicles Equipped With Snow Plows OVERVIEW: This bulletin provides information on how to program the Engine Control Module (ECM) to force the fan clutch to fully engage at all operating conditions MODELS: 2007 - 2010 DC/DM Ram 3500/4500/5500 Cab Chassis Trucks 2011 DD/DP Ram 3500/4500/5500 Cab Chassis Trucks NOTE: This bulletin applies to vehicles equipped with the 6.7L Cummins Diesel engine (Sales Code ETJ) DISCUSSION: Customers that operate their vehicle with a snowplow attached to the vehicle may cause the airflow passing through the radiator to be disrupted resulting in higher than normal engine temperatures The 6~7L Cummins ECM is equipped with software that can fully engage the fan clutch to allow an increase of airflow through the radiator Customers can initiate the fan clutch operation by performing the following button sequence NOTE: 2007 early 2009 models were not originally equipped with the fan clutch software however, recently released software does include this enhancement Ensure that the ECM software is at the latest level and if not, flash the ECM Refer to Service Bulletin 18-020-10 for additional information 1. Turn the ignition key to the run position or start the truck 2. Simultaneously press and release the Cruise Control "Cancel" button/lever and the "Exhaust Brake" button. Repeat this sequence four times within five seconds. The chime will sound twice as an audible indicator that the function is engaged 3. To disable the function, repeat the same procedure The chime will sound four times as an audible indicator that the function is disengaged NOTE: Customer's should be made aware that an increase in fan noise and a decrease in fuel economy may result when using this feature. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Systems/Exhaust Enhancements NUMBER: 18-020-10 GROUP: Vehicle Performance DATE: June 10, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-06, DATED DECEMBER 05, 2006 AND 18-001-09, DATED JANUARY 21, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. Either wiTECH OR StarMOBILE DESKTOP CLIENT can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. StarMOBILE® SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. SUBJECT: FLASH: Engine Systems And Exhaust Aftertreatment Systems Enhancements OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement based on customer use and mileage accumulation. This bulletin involves: ^ Selectively erasing and reprogramming the Engine Control Module (PCM), 2007 - 2010 MY. ^ Selectively erasing and reprogramming the Cab Compartment Node (CCN), 2007 & 2008 MY. ^ If CCN is updated; provide a Customer Information Sheet explaining the overhead display messages. ^ One of several software changes allows for "Net Zero" and "Net Reduction" which will cause noticeable changes in idle speeds. Customers should be informed of these changes. They are explained in DISCUSSION, Improvements that address erroneous MIL illumination for DTC P0106, P0191, P2262 and P2299 DTC's, (spelled out in DISCUSSION below). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. MODELS: 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) 2008 - 2010 (DM) Ram Truck (4500/5500 Cab Chassis) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). NOTE: For some 2007 MY vehicles, the ECM flash is addressed in Recall K01, Dated May, 2010. Where applicable. please use the Recall to update the ECM and this bulletin to update the CCN software. DISCUSSION: Cab chassis trucks equipped with a 6.7L Cummins diesel have a number of software improvements available. This latest Service Bulletin (SB) will include improvements to prevent erroneous Malfunction Indicator Lamp (MIL) illumination: ^ P000F - Fuel System Over Pressure Relief Valve Activated Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 345 ^ P0087 - Fuel Rail Pressure Too Low ^ P0106 - Manifold Absolute Pressure Sensor Performance ^ P0191 - Fuel Rail Pressure Sensor Circuit Performance ^ P1011 - Fuel Pump Delivery Pressure Too Low ^ P2299 - Brake Pedal Position / Accelerator Pedal Position Incompatible ^ P2262 - Turbocharger Boost Pressure Not Detected - Mechanical Other updates will include the following operational and diagnostic improvements: 1. Stationary DeSoot is now available with this software. This feature works similar to pick up truck (DH/D1) models. 2. New DTC added for P2563 - Turbocharger Boost Control Position Sensor Performance. This DTC indicates diminished variable geometry turbocharger travel, which is resolved by replacing the turbocharger. Diagnosis and repair procedures for the DTC have been published in DTC-Based Diagnostics in TechConnect. 3. The latest PCM software includes a new extended idle feature to accommodate the extended idle times present in some duty cycles. This feature may help to reduce the accumulation of soot in the exhaust aftertreatment system when the engine is idling for an extended period of time. Briefly how this feature works: a. As needed, the engine enters an idling mode which dramatically reduces the rate of soot accumulation in the diesel particulate filter (called "Net Zero"). Further, under extended idle periods of 5 minutes or longer, the engine enters a mode which reduces the amount of soot accumulated in the diesel particulate filter (called "Net Reduction"). While in these modes, the idle speed increases to 900 RPM for a period of time. The idle speed may return to normal idle speed and then return to 900 RPM to repeat this cycle during very long idle periods. b. These modes occur automatically depending on the need to regenerate the DPF as long as the vehicle is not driven over 20 MPH or operated at high load. If the vehicle is driven over 20 MPH normal mobile desoot will occur automatically. 4. New scan tool driven fuel system diagnostic tests (same as previously released in the pick up) now available for cab chassis. DIAGNOSIS: 1. Using the scan tool, determine current software level of the PCM and CCN. Record on the repair order, for later use, the current PCM and CCN software level part numbers. Proceed to the next step. 2. Compare the current PCM software level part number with software available in the scantool. Determine if the current PCM software level part number, recorded in Step # 1, is programmable to a higher level. 3. Is the part number of the current PCM level software (recorded in Step # 1) at the latest level listed in the scan tool? a. If YES >> then the PCM DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. b. If NO >> then the PCM DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. 4. Is the vehicle a 2007 OR 2008 MY? a. Yes >>> Proceed to Step # 5. b. No >>> 2009 MY proceed to the REPAIR PROCEDURE as required. 5. Determine if the current CCN module level software part number, that was recorded earlier in Step # 1, is one of the following (or with a higher suffix): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 346 a. 05172187AH (or higher) = 2007 DC (3500). b. 05172334AG (or higher) = 2008 DC (3500) / DM (3500/4500). c. 2009 & 2010 MY vehicles came equipped with proper CCN software. 6. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 5? a. If YES >>> then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. b. If NO >>> then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. PARTS REQUIRED: REPAIR PROCEDURE; ECM MODULE REPROGRAM: NOTE: The wiTECH diagnostic application is the preferred method for flashing ECU's. Help using the wiTECH diagnostic application for flashing an ECU is available by selecting "Help" then "Help Contents" at the top of the wiTECH diagnostic application window. NOTE: The wiTECH software level must be at release 10.04 or higher to perform this procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. If required, as determined in DIAGNOSIS, above: reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > 8E - Electronic Control Modules >MODULE, Engine Control, Diesel > Service Information > Standard Procedure > PCM/ECM Programming - DIESEL. After PCM reprogramming, the following must be performed: a. Clear any DIG's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 3. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. 4. If required, as determined in DIAGNOSIS, above: reprogram the CCN using one of the following procedures, (based on scan tool use). 5. Was it determined in DIAGNOSIS, Step # 6 above, the CCN required updating? a. Yes >>> Proceed to appropriate CCN Module Reprogram Procedure Below, based on the scantool used. b. No >>> Repair is complete. NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 347 NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. CCN MODULE REPROGRAM - USING wiTECH(R): 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id and "Password", then select "OK". 6. Select the "Next tab at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash" screen follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF position", remove the wiPOD(R) and battery charger from the vehicle. StarMOBILE(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident" flash file for statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 348 b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step Se, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number (displayed at the end of the "Resident flash file for statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 349 Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "Exhaust Filter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required - See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test Engine Control Module: All Technical Service Bulletins Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 354 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 359 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 360 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness Technical Service Bulletin # K01 Date: 100510 Recall - ECM Update For OBD Readiness May 2010 Dealer Service Instructions for: California Emissions Recall K01 Reprogram ECM OBD Readiness Effective immediately all repairs on involved vehicles are to be performed according to this notification. Service Bulletin 18-038-09 is no longer applicable for the involved vehicles only. Models 2003 (DR) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETC) and a California emission control system (sales code NAE). 2006-2007 (DH/D1) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETH) and a California emission control system (sales code NAE). 2007 (DC) Dodge Ram Truck (3500 series cab chassis) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ) and a California emission control system (sales code NAE) built through January 5, 2007 (MDH010508). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process or GRS DealerCONNECT functions. Subject The Engine Control Module (ECM) on about 25,208 of the above vehicles may fail to accurately report diagnostic system information with some generic scan tools. This may cause the vehicle to be rejected or fail an Inspection/Maintenance Test (also known as a Smog Check). Repair The Engine Control Module (ECM) must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Part Number Description 04275086AB Authorized Modifications Label Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 365 The special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the label plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 366 To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: The DRBIII(R) must be used to perform this recall on 2003 Model Year (MY) vehicles. The 2003 MY procedure is found in Section D of the Service Procedure. Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall on 2006-2007 MY vehicles. This procedure must be performed with software release level 10.03 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 367 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's" button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section E. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 368 h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section E. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 369 e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 10. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 9. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 10. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 11. Continue with Section E. Install Authorized Modification Label. D. Reprogram the ECM Using DRBIII(R): The DealerCONNECT System, DRBIII(R) (Diagnostic Readout Box scan tool), CH7000A flash cable and CH7035B data cable are required to perform this repair. Do not attempt to perform the flash procedure using an outdated CH7000/CH7001 flash cable. NOTE: Whenever a controller is reprogrammed, the software in the DRBIII scan tool must be programmed with the latest revision level available. NOTE: If the flash process is interrupted or aborted, the flash should be restarted and then follow the directions on the DRBIII scan tool. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 370 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the DRBIII CH7000A flash cable from the DRBIII scan tool to the data link connector located inside the vehicle under the steering column. 3. Connect the CH7035B data cable from the DealerCONNECT machine to the MDS port on the DRBIII scan tool. 4. Place the vehicle's ignition key in the "RUN" position. 5. From the DealerCONNECT "WELCOME" screen, enter your "User I.D.," "Password" and "Dealer Code". 6. From the DealerCONNECT "HOME PAGE" select the "SERVICE" tab. 7. From the "SERVICE" tab screen select "TechTOOLS". 8. If the DRBIII scan tool does not "Auto Connect" select # 2 on the DRBIII key pad "Connect to TechCONNECT". 9. After the "Auto Connect" process is complete, select "READ PART NUMBER(S) FROM VEHICLE" on the TechCONNECT screen. 10. Continue following the TechCONNECT on-screen instructions. 11. Select the applicable update calibration. 12. Select the "DRBIII" button located at the bottom of the TechCONNECT monitor screen. 13. Select the "DOWNLOAD / UPDATE" button located next to the "DRBIII" button. NOTE: The system software will automatically download to the DRBIII scan tool. 14. After the software download to the DRBIII scan tool is complete, close the "DOWNLOAD / UPDATE PROGRESS" window. 15. Disconnect the DRBIII scan tool from the TechCONNECT CH7035B data cable. 16. Select # 1 "RETURN TO NORMAL MODE" on the DRBIII scan tool. 17. Use the following procedure to download the flash from the DRBIII scan tool to the vehicle. a. Select # 7 "VEHICLE FLASH" on the DRBIII scan tool. b. Follow the directions displayed on the DRBIII scan tool screen. c. After the reprogramming is complete, record the new module part number displayed on the DRBIII scan tool screen. d. Press the "PAGE BACK" button on the DRBIII scan tool. 18. Due to the ECM flash procedure, Diagnostic Trouble Codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS, ORC) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules, record the trouble codes, and erase the trouble codes using the following procedure: a. Turn the vehicle's ignition key to the "RUN" position. b. From the DRBIII scan tool Main Menu select # 1 "DRBIII Stand-Alone". c. From the DRBIII scan tool Stand-Alone menu select # 3 "Vehicle Module Scan". d. From the DRBIII scan tool Vehicle Module Scan menu select # 1 "1998 - 2005 Module Scan". e. Select "YES" on the DRBIII scan tool key pad to scan for DTC's. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 371 f. Follow the instructions on the DRBIII scan tool screen. g. Once the scanning process is complete, the DRBIII scan tool will display a list of all the modules. Modules on the list that have an asterisk next to them have DTC's that need to be cleared. h. Select the module that needs to have the DTC's cleared and follow the instructions on the DRBIII scan tool screen to clear the DTC's. i. Turn the vehicle's ignition key to the "OFF" position. NOTE: Erase any DTC's in the ECM only after all other modules have had their DTC's erased. 19. Disconnect the DRBIII scan tool from the vehicle. 20. Turn off the battery charger and disconnect it from the vehicle. 21. Continue with Section E. Install Authorized Modification Label. E. Install the Authorized Modifications Label: 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 372 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 377 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 378 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 379 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 380 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 385 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 386 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 387 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 388 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 389 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 390 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 391 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-030-07 > Apr > 07 > Engine Controls - Engine Off Idle Speed Limit Feature Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Off Idle Speed Limit Feature NUMBER: 18-030-07 GROUP: Vehicle Performance DATE: April 26, 2007 SUBJECT: Engine Off-Idle Speed Limit Feature To Protect Turbocharger When Vehicle Is Not Moving OVERVIEW: This bulletin involves a discussion regarding an engine control feature that limits engine off-idle speeds when the vehicle is not moving. MODELS: 2004 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 5.9L or a 6.7L Cummins turbo-diesel engine (sale codes: ETC, ETH, or ETJ). DISCUSSION: Dependent upon engine coolant temperature, the Engine Control Module (ECM) will temporarily delay (limit) the maximum engine speed when the vehicle is not moving. For automatic transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph, and when the transmission selector is in either the neutral or park position. For manual transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph. This ECM feature is used to protect the engine turbocharger. By temporarily limiting the vehicle engine speed, the shaft speed of the engine turbocharger is controlled to a low speed. This delay in maximum engine and turbo-charger shaft speed allows for sufficient oil lubrication to the turbocharger shaft bearings. Satisfactory oil lubrication of the turbocharger shaft bearings is important for long term turbocharger durability. The maximum engine speed for the 5.9L engine is temporarily limited to 1,600 RPM's when the above conditions are met. The 6.7L engine speed is temporarily limited to 1,200 RPM's when the above conditions are met. The length of time that the maximum engine speed is temporarily limited is dependent upon engine coolant temperature. Refer to the table to determine the amount of Time Delay. NOTE: The time delay values supplied in the table are an approximation and may vary per application. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Engine Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 400 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 401 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 402 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 07-003-10 > Sep > 10 > Engine Controls - ECM Update for Fan Clutch Operation Engine Control Module: All Technical Service Bulletins Engine Controls - ECM Update for Fan Clutch Operation NUMBER: 07-003-10 GROUP: Cooling DATE: September 09, 2010 SUBJECT: High Coolant Temperatures On Vehicles Equipped With Snow Plows OVERVIEW: This bulletin provides information on how to program the Engine Control Module (ECM) to force the fan clutch to fully engage at all operating conditions MODELS: 2007 - 2010 DC/DM Ram 3500/4500/5500 Cab Chassis Trucks 2011 DD/DP Ram 3500/4500/5500 Cab Chassis Trucks NOTE: This bulletin applies to vehicles equipped with the 6.7L Cummins Diesel engine (Sales Code ETJ) DISCUSSION: Customers that operate their vehicle with a snowplow attached to the vehicle may cause the airflow passing through the radiator to be disrupted resulting in higher than normal engine temperatures The 6~7L Cummins ECM is equipped with software that can fully engage the fan clutch to allow an increase of airflow through the radiator Customers can initiate the fan clutch operation by performing the following button sequence NOTE: 2007 early 2009 models were not originally equipped with the fan clutch software however, recently released software does include this enhancement Ensure that the ECM software is at the latest level and if not, flash the ECM Refer to Service Bulletin 18-020-10 for additional information 1. Turn the ignition key to the run position or start the truck 2. Simultaneously press and release the Cruise Control "Cancel" button/lever and the "Exhaust Brake" button. Repeat this sequence four times within five seconds. The chime will sound twice as an audible indicator that the function is engaged 3. To disable the function, repeat the same procedure The chime will sound four times as an audible indicator that the function is disengaged NOTE: Customer's should be made aware that an increase in fan noise and a decrease in fuel economy may result when using this feature. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Systems/Exhaust Enhancements NUMBER: 18-020-10 GROUP: Vehicle Performance DATE: June 10, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-06, DATED DECEMBER 05, 2006 AND 18-001-09, DATED JANUARY 21, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. Either wiTECH OR StarMOBILE DESKTOP CLIENT can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. StarMOBILE® SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. SUBJECT: FLASH: Engine Systems And Exhaust Aftertreatment Systems Enhancements OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement based on customer use and mileage accumulation. This bulletin involves: ^ Selectively erasing and reprogramming the Engine Control Module (PCM), 2007 - 2010 MY. ^ Selectively erasing and reprogramming the Cab Compartment Node (CCN), 2007 & 2008 MY. ^ If CCN is updated; provide a Customer Information Sheet explaining the overhead display messages. ^ One of several software changes allows for "Net Zero" and "Net Reduction" which will cause noticeable changes in idle speeds. Customers should be informed of these changes. They are explained in DISCUSSION, Improvements that address erroneous MIL illumination for DTC P0106, P0191, P2262 and P2299 DTC's, (spelled out in DISCUSSION below). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. MODELS: 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) 2008 - 2010 (DM) Ram Truck (4500/5500 Cab Chassis) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). NOTE: For some 2007 MY vehicles, the ECM flash is addressed in Recall K01, Dated May, 2010. Where applicable. please use the Recall to update the ECM and this bulletin to update the CCN software. DISCUSSION: Cab chassis trucks equipped with a 6.7L Cummins diesel have a number of software improvements available. This latest Service Bulletin (SB) will include improvements to prevent erroneous Malfunction Indicator Lamp (MIL) illumination: ^ P000F - Fuel System Over Pressure Relief Valve Activated Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 412 ^ P0087 - Fuel Rail Pressure Too Low ^ P0106 - Manifold Absolute Pressure Sensor Performance ^ P0191 - Fuel Rail Pressure Sensor Circuit Performance ^ P1011 - Fuel Pump Delivery Pressure Too Low ^ P2299 - Brake Pedal Position / Accelerator Pedal Position Incompatible ^ P2262 - Turbocharger Boost Pressure Not Detected - Mechanical Other updates will include the following operational and diagnostic improvements: 1. Stationary DeSoot is now available with this software. This feature works similar to pick up truck (DH/D1) models. 2. New DTC added for P2563 - Turbocharger Boost Control Position Sensor Performance. This DTC indicates diminished variable geometry turbocharger travel, which is resolved by replacing the turbocharger. Diagnosis and repair procedures for the DTC have been published in DTC-Based Diagnostics in TechConnect. 3. The latest PCM software includes a new extended idle feature to accommodate the extended idle times present in some duty cycles. This feature may help to reduce the accumulation of soot in the exhaust aftertreatment system when the engine is idling for an extended period of time. Briefly how this feature works: a. As needed, the engine enters an idling mode which dramatically reduces the rate of soot accumulation in the diesel particulate filter (called "Net Zero"). Further, under extended idle periods of 5 minutes or longer, the engine enters a mode which reduces the amount of soot accumulated in the diesel particulate filter (called "Net Reduction"). While in these modes, the idle speed increases to 900 RPM for a period of time. The idle speed may return to normal idle speed and then return to 900 RPM to repeat this cycle during very long idle periods. b. These modes occur automatically depending on the need to regenerate the DPF as long as the vehicle is not driven over 20 MPH or operated at high load. If the vehicle is driven over 20 MPH normal mobile desoot will occur automatically. 4. New scan tool driven fuel system diagnostic tests (same as previously released in the pick up) now available for cab chassis. DIAGNOSIS: 1. Using the scan tool, determine current software level of the PCM and CCN. Record on the repair order, for later use, the current PCM and CCN software level part numbers. Proceed to the next step. 2. Compare the current PCM software level part number with software available in the scantool. Determine if the current PCM software level part number, recorded in Step # 1, is programmable to a higher level. 3. Is the part number of the current PCM level software (recorded in Step # 1) at the latest level listed in the scan tool? a. If YES >> then the PCM DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. b. If NO >> then the PCM DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. 4. Is the vehicle a 2007 OR 2008 MY? a. Yes >>> Proceed to Step # 5. b. No >>> 2009 MY proceed to the REPAIR PROCEDURE as required. 5. Determine if the current CCN module level software part number, that was recorded earlier in Step # 1, is one of the following (or with a higher suffix): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 413 a. 05172187AH (or higher) = 2007 DC (3500). b. 05172334AG (or higher) = 2008 DC (3500) / DM (3500/4500). c. 2009 & 2010 MY vehicles came equipped with proper CCN software. 6. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 5? a. If YES >>> then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. b. If NO >>> then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. PARTS REQUIRED: REPAIR PROCEDURE; ECM MODULE REPROGRAM: NOTE: The wiTECH diagnostic application is the preferred method for flashing ECU's. Help using the wiTECH diagnostic application for flashing an ECU is available by selecting "Help" then "Help Contents" at the top of the wiTECH diagnostic application window. NOTE: The wiTECH software level must be at release 10.04 or higher to perform this procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. If required, as determined in DIAGNOSIS, above: reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > 8E - Electronic Control Modules >MODULE, Engine Control, Diesel > Service Information > Standard Procedure > PCM/ECM Programming - DIESEL. After PCM reprogramming, the following must be performed: a. Clear any DIG's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 3. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. 4. If required, as determined in DIAGNOSIS, above: reprogram the CCN using one of the following procedures, (based on scan tool use). 5. Was it determined in DIAGNOSIS, Step # 6 above, the CCN required updating? a. Yes >>> Proceed to appropriate CCN Module Reprogram Procedure Below, based on the scantool used. b. No >>> Repair is complete. NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 414 NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. CCN MODULE REPROGRAM - USING wiTECH(R): 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id and "Password", then select "OK". 6. Select the "Next tab at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash" screen follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF position", remove the wiPOD(R) and battery charger from the vehicle. StarMOBILE(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident" flash file for statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 415 b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step Se, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number (displayed at the end of the "Resident flash file for statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 416 Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "Exhaust Filter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required - See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test Engine Control Module: All Technical Service Bulletins Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 421 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 426 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 427 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 432 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 433 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 434 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 435 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-030-07 > Apr > 07 > Engine Controls - Engine Off Idle Speed Limit Feature Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Off Idle Speed Limit Feature NUMBER: 18-030-07 GROUP: Vehicle Performance DATE: April 26, 2007 SUBJECT: Engine Off-Idle Speed Limit Feature To Protect Turbocharger When Vehicle Is Not Moving OVERVIEW: This bulletin involves a discussion regarding an engine control feature that limits engine off-idle speeds when the vehicle is not moving. MODELS: 2004 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 5.9L or a 6.7L Cummins turbo-diesel engine (sale codes: ETC, ETH, or ETJ). DISCUSSION: Dependent upon engine coolant temperature, the Engine Control Module (ECM) will temporarily delay (limit) the maximum engine speed when the vehicle is not moving. For automatic transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph, and when the transmission selector is in either the neutral or park position. For manual transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph. This ECM feature is used to protect the engine turbocharger. By temporarily limiting the vehicle engine speed, the shaft speed of the engine turbocharger is controlled to a low speed. This delay in maximum engine and turbo-charger shaft speed allows for sufficient oil lubrication to the turbocharger shaft bearings. Satisfactory oil lubrication of the turbocharger shaft bearings is important for long term turbocharger durability. The maximum engine speed for the 5.9L engine is temporarily limited to 1,600 RPM's when the above conditions are met. The 6.7L engine speed is temporarily limited to 1,200 RPM's when the above conditions are met. The length of time that the maximum engine speed is temporarily limited is dependent upon engine coolant temperature. Refer to the table to determine the amount of Time Delay. NOTE: The time delay values supplied in the table are an approximation and may vary per application. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Engine Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 444 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 445 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 446 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness Technical Service Bulletin # K01 Date: 100510 Recall - ECM Update For OBD Readiness May 2010 Dealer Service Instructions for: California Emissions Recall K01 Reprogram ECM OBD Readiness Effective immediately all repairs on involved vehicles are to be performed according to this notification. Service Bulletin 18-038-09 is no longer applicable for the involved vehicles only. Models 2003 (DR) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETC) and a California emission control system (sales code NAE). 2006-2007 (DH/D1) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETH) and a California emission control system (sales code NAE). 2007 (DC) Dodge Ram Truck (3500 series cab chassis) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ) and a California emission control system (sales code NAE) built through January 5, 2007 (MDH010508). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process or GRS DealerCONNECT functions. Subject The Engine Control Module (ECM) on about 25,208 of the above vehicles may fail to accurately report diagnostic system information with some generic scan tools. This may cause the vehicle to be rejected or fail an Inspection/Maintenance Test (also known as a Smog Check). Repair The Engine Control Module (ECM) must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Part Number Description 04275086AB Authorized Modifications Label Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 452 The special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the label plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 453 To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: The DRBIII(R) must be used to perform this recall on 2003 Model Year (MY) vehicles. The 2003 MY procedure is found in Section D of the Service Procedure. Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall on 2006-2007 MY vehicles. This procedure must be performed with software release level 10.03 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 454 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's" button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section E. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 455 h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section E. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 456 e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 10. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 9. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 10. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 11. Continue with Section E. Install Authorized Modification Label. D. Reprogram the ECM Using DRBIII(R): The DealerCONNECT System, DRBIII(R) (Diagnostic Readout Box scan tool), CH7000A flash cable and CH7035B data cable are required to perform this repair. Do not attempt to perform the flash procedure using an outdated CH7000/CH7001 flash cable. NOTE: Whenever a controller is reprogrammed, the software in the DRBIII scan tool must be programmed with the latest revision level available. NOTE: If the flash process is interrupted or aborted, the flash should be restarted and then follow the directions on the DRBIII scan tool. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 457 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the DRBIII CH7000A flash cable from the DRBIII scan tool to the data link connector located inside the vehicle under the steering column. 3. Connect the CH7035B data cable from the DealerCONNECT machine to the MDS port on the DRBIII scan tool. 4. Place the vehicle's ignition key in the "RUN" position. 5. From the DealerCONNECT "WELCOME" screen, enter your "User I.D.," "Password" and "Dealer Code". 6. From the DealerCONNECT "HOME PAGE" select the "SERVICE" tab. 7. From the "SERVICE" tab screen select "TechTOOLS". 8. If the DRBIII scan tool does not "Auto Connect" select # 2 on the DRBIII key pad "Connect to TechCONNECT". 9. After the "Auto Connect" process is complete, select "READ PART NUMBER(S) FROM VEHICLE" on the TechCONNECT screen. 10. Continue following the TechCONNECT on-screen instructions. 11. Select the applicable update calibration. 12. Select the "DRBIII" button located at the bottom of the TechCONNECT monitor screen. 13. Select the "DOWNLOAD / UPDATE" button located next to the "DRBIII" button. NOTE: The system software will automatically download to the DRBIII scan tool. 14. After the software download to the DRBIII scan tool is complete, close the "DOWNLOAD / UPDATE PROGRESS" window. 15. Disconnect the DRBIII scan tool from the TechCONNECT CH7035B data cable. 16. Select # 1 "RETURN TO NORMAL MODE" on the DRBIII scan tool. 17. Use the following procedure to download the flash from the DRBIII scan tool to the vehicle. a. Select # 7 "VEHICLE FLASH" on the DRBIII scan tool. b. Follow the directions displayed on the DRBIII scan tool screen. c. After the reprogramming is complete, record the new module part number displayed on the DRBIII scan tool screen. d. Press the "PAGE BACK" button on the DRBIII scan tool. 18. Due to the ECM flash procedure, Diagnostic Trouble Codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS, ORC) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules, record the trouble codes, and erase the trouble codes using the following procedure: a. Turn the vehicle's ignition key to the "RUN" position. b. From the DRBIII scan tool Main Menu select # 1 "DRBIII Stand-Alone". c. From the DRBIII scan tool Stand-Alone menu select # 3 "Vehicle Module Scan". d. From the DRBIII scan tool Vehicle Module Scan menu select # 1 "1998 - 2005 Module Scan". e. Select "YES" on the DRBIII scan tool key pad to scan for DTC's. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 458 f. Follow the instructions on the DRBIII scan tool screen. g. Once the scanning process is complete, the DRBIII scan tool will display a list of all the modules. Modules on the list that have an asterisk next to them have DTC's that need to be cleared. h. Select the module that needs to have the DTC's cleared and follow the instructions on the DRBIII scan tool screen to clear the DTC's. i. Turn the vehicle's ignition key to the "OFF" position. NOTE: Erase any DTC's in the ECM only after all other modules have had their DTC's erased. 19. Disconnect the DRBIII scan tool from the vehicle. 20. Turn off the battery charger and disconnect it from the vehicle. 21. Continue with Section E. Install Authorized Modification Label. E. Install the Authorized Modifications Label: 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 459 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 464 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 465 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 466 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 467 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 468 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 469 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 470 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 479 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 480 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 481 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control Engine Control Module: Locations Module-Engine Control Component ID: 203 Component : MODULE-ENGINE CONTROL Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (5.9L) Pin Description Circuit 1 WASTEGATE SOLENOID CONTROL K139 18DB 2 OIL PRESSURE SIGNAL G6 18VT/GY 3-4 CAN C BUS (+) D65 18WT/LG 5 CAN C BUS (-) D64 18WT/LB 6 FUEL CONTROL ACTUATOR RETURN K65 18BR/LB 7 GEN FIELD CONTROL K20 18BR/GY 8 TTVA MOTOR (+) K314 18TN/YL 9-10 - 11 WATER IN FUEL SENSOR GROUND K923 18BR/WT 12 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 13 INLET AIR TEMPERATURE SENSE K615 18VT/WT 14 - 15 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 16 INLET AIR PRESSURE SENSE K616 18BR/YL 17 ECT SIGNAL K2 18VT/OR 18 - 19 FUEL CONTROL ACTUATOR DRIVER K604 18BR/TN 20 TTVA MOTOR (-) K315 18TN/OR 21 FAN SPEED SENSOR GROUND K161 18BR/LB 22 CKP SIGNAL K24 18BR/LB 23 SENSOR GROUND K200 18BR/YL 24 CMP SIGNAL K44 18DB/GY 25 5 VOLT SUPPLY K668 18BR 26 - 27 5 VOLT SUPPLY K853 18DB/BR 28 - 29 SENSOR GROUND K690 18BR/YL 30 INJECTOR CONTROL NO. 1 K11 16BR/YL 31 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG 32 CMP SENSOR GROUND K944 18BK/GY Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 484 33 APPS NO. 1 RETURN K167 18BR/YL 34 FAN SPEED SENSOR SIGNAL N210 18DB/DG 35 - 36 INJECTOR CONTROL NO. 4 K14 16BR/TN 37 - 38 - 39 - 40 INJECTOR CONTROL NO. 3 K13 16TN 41 SENSOR GROUND K210 18DB/TN 42 5 VOLT SUPPLY K852 18BR/VT 43 BOOST PRESSURE SENSOR SIGNAL K37 18LB 44 - 45 - 46 INJECTOR CONTROL NO. 6 K58 16BR/VT 47 - 48 - 49 - 50 INJECTOR CONTROL NO. 2 K12 16BR/DB 51 - 52 CKP SENSOR GROUND K975 18BR/OR 53 FUEL RAIL SENSOR RETURN K915 18BR/WT 54 5 VOLT SUPPLY F855 18PK/YL 55 - 56 INJECTOR CONTROL NO. 5 K38 16GY 57 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 16TN/PK 58 - 59 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 16BR/LG 60 - Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 485 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 486 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 487 Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 2 EGR CONTROL NO. 1 K682 18DB/WT 3 EGR CONTROL NO. 2 K684 18DB/YL 4 EGR CONTROL NO. 3 K686 18GY/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 488 5 EGR SIGNAL NO. 2 K685 18DB 6-7 FAN SPEED SENSOR GROUND K161 18BR/LB 8-9 EGR BYPASS VALVE SIGNAL K670 18BR/LB 10 FUEL CONTROL ACTUATOR RETURN K366 18BR/LB 11 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 12 - 13 EGR AIRFLOW CONTROL VALVE MOTOR (-) K314 18BR 14 CRANKCASE SENSOR SIGNAL K926 18DB/GY 15 ECT SIGNAL K2 18VT/OR 16 - 17 EGR BYPASS STATUS K671 18BR/DB 18 FAN SPEED SENSOR SIGNAL N27 18DB/GY 19 BOOST PRESSURE SENSOR SIGNAL K37 18BR 20 INLET AIR PRESSURE SENSE K616 18BR/YL 21 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 22 SENSOR GROUND K971 18BR/PK 23 - 24 INLET AIR TEMPERATURE SENSE K615 18VT/WT 25 EGR SIGNAL NO. 1 K683 18DB/GY 26 5 VOLT SUPPLY K824 18DB/BR 27 EGR AIRFLOW CONTROL VALVE MOTOR (+) K158 18BR/YL 28 GEN SENSE A804 18RD 29 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 30 FUEL CONTROL ACTUATOR DRIVER K365 18DB/BR 31 CKP SIGNAL K24 18BR/LB 32 OIL PRESSURE SIGNAL G6 18VT/GY 33 ACTUATOR GROUND K972 18DB/TN 34 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG 35 EGR SIGNAL NO. 3 K687 18DB/LB 36 5 VOLT SUPPLY F855 18PK/YL 37 CMP SIGNAL K44 18DB/GY 38 ACTUATOR HIGH DATA LINK D130 18BR/VT 39 ACTUATOR LOW DATA LINK D131 18WT/LG 40 GEN FIELD CONTROL K20 18BR/GY 41 EGR TEMPERATURE SENSOR SIGNAL K935 18DB 42 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 43 TURBO SPEED SENSOR GROUND K541 18BR/VT 44 CKP SENSOR GROUND K925 18BR/OR 45 INJECTOR CONTROL NO. 6 K58 16BR/VT 46 INJECTOR CONTROL NO. 2 K12 16BR/DB 47 SENSOR GROUND K914 18BR/WT 48 SENSOR GROUND K916 18BR/OR 49 - 50 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG 51 INJECTOR HIGH SIDE DRIVER NO. 3 K613 16GY/BR 52 INJECTOR HIGH SIDE DRIVER NO. 2 K612 16YL/BR 53 INJECTOR HIGH SIDE DRIVER NO. 1 K611 16OR/BR 54 INJECTOR CONTROL NO. 4 K14 16BR/TN 55 INJECTOR CONTROL NO. 5 K38 16GY 56 INJECTOR CONTROL NO. 3 K13 16TN 57 INJECTOR CONTROL NO. 1 K11 16BR/YL 58 INJECTOR HIGH SIDE DRIVER NO. 6 K658 16LG/BR 59 INJECTOR HIGH SIDE DRIVER NO. 5 K638 16LB/BR 60 INJECTOR HIGH SIDE DRIVER NO. 4 K614 16WT/BR Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 489 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 490 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 491 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 50 Qualifier : (5.9L) Pin Description Circuit 1-2-3 APPS NO. 1 SIGNAL K23 18BR/WT 4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 492 5 TRANSMISSION CONTROL T515 18YL/DB 6 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 7 FUEL PUMP CONTROL K31 18BR 8-9 TRS T41 SIGNAL (P/N) T41 18YL/DB 10 - 11 - 12 - 13 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 18DG 14 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 15 3-4 SOLENOID CONTROL T9 18DG/TN 16 - 17 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 18 - 19 - 20 FUSED B(+) A209 16RD 21 GROUND Z902 16BK 22 - 23 5 VOLT SUPPLY F856 18YL/PK 24 SENSOR GROUND K900 18DB/DG 25 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 26 - 27 TTVA POSITION SENSOR SIGNAL K312 18OR 28 - 29 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR 30 FUSED B(+) A209 16RD 31 - 32 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 33 5 VOLT SUPPLY K854 18VT/BR 34 - 35 APPS NO. 2 SIGNAL K29 18WT/BR 36 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 37 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 38 - 39 - 40 FUSED B(+) A209 16RD 41 A/C CLUTCH CONTROL C13 18LB/OR 42 - 43 PWM FAN COIL SIGNAL K160 18BR/OR 44 OUTPUT SPEED SIGNAL T14 18DG/BR 45 SPEED SENSOR GROUND T13 18DG/VT 46 S/C SWITCH NO. 1 SIGNAL V37 18VT 47 BATT TEMP SIGNAL K25 18DB/VT 48 APPS NO. 2 RETURN K400 18BR/VT 49 GROUND Z902 16BK 50 GROUND Z902 16BK Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 493 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 494 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 495 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 CAN C BUS (+) D65 18WT/LG 2 FUEL PUMP CONTROL K31 18BR 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 496 5 EXHAUST BRAKE SWITCH SIGNAL G905 18BR/OR 6 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 7 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 8 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 9 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/OR 10 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 11 - 12 - 13 - 14 - 15 CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT T26 18DG/OR 16 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 17 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 18 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 19 - 20 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 21 CAN C BUS (-) D64 18WT/LB 22 APPS NO. 2 RETURN K400 18BR/VT 23 - 24 APPS NO. 2 SIGNAL K29 18WT/BR 25 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 26 5 VOLT SUPPLY K854 18VT/BR 27 5 VOLT SUPPLY K852 18BR/LB 28 APPS NO. 1 RETURN K167 18BR/DG 29 SENSOR GROUND K900 18DB/DG 30 BATT TEMP SIGNAL K25 18DB/VT 31 DIAGNOSTIC PORT HIGH DATA LINK D133 18WT/OR 32 - 33 S/C SWITCH RETURN V937 18VT/BR 34 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 35 APPS NO. 1 SIGNAL K23 18BR/WT 36 - - 37 REMOTE THROTTLE SIGNAL K128 18DG/LG 38 - 39 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 40 S/C SWITCH NO. 1 SIGNAL V37 18VT 41 - 42 - 43 SMART POWER RELAY RETURN K348 18BR 44 A/C CLUTCH CONTROL C13 18LB 45 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 46 - 47 GROUND Z902 16BK 48 GROUND Z902 16BK 49 FUSED B(+) A209 16RD 50 FUSED B(+) A209 16RD 51 DIAGNOSTIC PORT LOW DATA LINK D132 18WT 52 - 53 - 54 EXHAUST BRAKE LAMP SIGNAL G904 18VT/DG 55 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 56 S/C SWITCH NO. 2 SIGNAL V38 18VT/OR 57 GROUND Z902 16BK 58 - 59 - 60 FUSED B(+) A209 16RD Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 497 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 498 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 499 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 500 Engine Control Module: Locations Module-Powertrain Control Component ID: 209 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Pin Description Circuit 123456- 789-10 11 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (RUN-START) F1 20PK/WT 13 14 15 16 17 18 - 19 SENSOR GROUND T160 20DG/WT 20 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 21 22 23 24 25 26 - 27 5 VOLT SUPPLY F856 20YL/PK 28 29 FUSED B(+) A918 20RD 30 IGNITION START T751 20YL 31 32 - Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 501 33 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 38 Component Location - 29 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 502 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 8 K98 18DB/YL 2-3 COIL CONTROL NO. 7 K97 18DB/YL 3 COIL CONTROL NO. 7 K97 18BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 503 4 INJECTOR CONTROL NO. 8 K28 18BR/LB 5 INJECTOR CONTROL NO. 7 K26 18BR/YL 6-7-8-9 GROUND Z130 16BK/BR 10 FUSED B(+) A918 16RD 11 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 13 - 14 - 15 - 16 - 17 - 18 GROUND Z131 16BK/DG 19 GROUND Z951 16BK/YL 20 OIL PRESSURE SIGNAL G6 16VT/GY 21 - 22 - 23 - 24 GEN SENSE A804 18RD/GY 25 - 27 5 VOLT SUPPLY F856 20YL/PK 28 MDS SOL CONTROL NO. 4 K452 20BR/LB 29 FUSED B(+) A918 16RD 30 IGNITION START T751 20YL 31 O2 1/2 SIGNAL K141 20DB/YL 32 O2 1/1 RETURN K902 20BR/DG 33 O2 2/2 SIGNAL K243 20BR 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 - - 38 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 504 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 505 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 6 K10 18DB/OR 2 COIL CONTROL NO. 5 K16 18DB/YL 3 COIL CONTROL NO. 4 K15 18DB/GY 4 INJECTOR CONTROL NO. 6 K58 18BR/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 506 5 INJECTOR CONTROL NO. 5 K38 18BR/OR 6 ETC MOTOR (+) K447 20TN/YL 7 COIL CONTROL NO. 3 K18 18DB/OR 8 EGR SOL CONTROL K35 20DB/VT 9 COIL CONTROL NO. 2 K17 18DB/TN 10 COIL CONTROL NO. 1 K19 18DB/DG 11 INJECTOR CONTROL NO. 4 K14 18BR/TN 12 INJECTOR CONTROL NO. 3 K13 18BR/LB 13 INJECTOR CONTROL NO. 2 K12 18BR/DB 14 INJECTOR CONTROL NO. 1 K11 18BR/YL 15 TP SENSOR RETURN K922 20BR/DB 16 MDS SOL CONTROL NO. 6 K453 20BR/DG 17 O2 2/1 HEATER CONTROL K199 20BR/VT 18 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 19 GEN FIELD CONTROL K20 18BR/GY 20 ECT SIGNAL K2 20VT/OR 21 TP NO. 1 SIGNAL K22 20BR/OR 22 EGR SIGNAL K34 20DB/LG 23 MAP SIGNAL K1 20VT/BR 24 KNOCK SENSOR NO. 1 RETURN K942 20BR/LG 25 KNOCK SENSOR NO. 1 SIGNAL K42 20DB/YL 26 - 27 SENSOR GROUND K900 20DB/DG 28 TP NO. 2 SIGNAL K122 20BR/DG 28 IAC SIGNAL K961 20BR/VT 29 5 VOLT SUPPLY F855 20PK/YL 30 IAT SIGNAL K21 20DB/LG 31 O2 1/1 SIGNAL K41 20DB/LB 32 O2 1/2 RETURN K904 20DB/DG 33 O2 2/1 SIGNAL K43 20DB/LG 34 CMP SIGNAL K44 20DB/GY 35 CKP SIGNAL K24 20BR/LB 36 KNOCK SENSOR NO. 2 SIGNAL K242 20BR/WT 37 KNOCK SENSOR NO. 2 RETURN K924 20WT/BR 38 ETC MOTOR (-) K448 20TN/OR 38 IAC CONTROL K61 20VT/GY Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 507 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 508 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1-2-3 ASD CONTROL K51 20BR/WT 4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 509 5 S/C VENT SOL CONTROL V35 20VT/OR 5 MDS SOL CONTROL NO. 7 K454 20BR/OR 6 MDS SOL CONTROL NO. 1 K451 20BR/WT 7 SPEED CONTROL SUPPLY V32 20VT/YL 8-9 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 10 O2 2/2 HEATER CONTROL K399 18BR/GY 11 A/C CLUTCH CONTROL C13 20LB/OR 12 S/C VACUUM SOL CONTROL V36 20VT/YL 13 - 14 BRAKE SWITCH NO. 2 SIGNAL V32 20VT/YL 15 S/C SWITCH RETURN V937 20VT/BR 16 APPS NO. 1 RETURN K167 20BR/YL 17 APPS NO. 2 RETURN K400 20BR/VT 18 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 19 ASD CONTROL OUTPUT K342 16BR/WT 20 EVAP PURGE SOL CONTROL K52 20DB/WT 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 PTO SENSE G113 20VT 22 PTO SENSE G113 18PK/YL 23 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT 24 - 25 APPS NO. 1 SIGNAL K23 20BR/WT 26 - 27 - 28 ASD CONTROL OUTPUT K342 16BR/WT 29 EVAP PURGE SOL SIGNAL K70 20DB/BR 30 P/S SWITCH SIGNAL K66 20DB/WT 31 - 32 - 33 OIL TEMPERATURE SIGNAL G24 20VT/BR 34 S/C SWITCH NO. 1 SIGNAL V37 20VT 35 ESM SIGNAL K107 20VT/WT 36 APPS NO. 2 SIGNAL K29 20WT/BR 37 FUEL PUMP CONTROL K31 20BR 38 STARTER SOLENOID CONTROL T752 20DG/OR Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 510 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 511 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Description Circuit 1 SENSOR GROUND T160 20YL/GY 2 4C CONTROL T259 20YL/DG 34 MS CONTROL T140 20YL/GY Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 512 5- 6 2C CONTROL T219 20YL/LG 78 UD CONTROL T59 20YL/LB 910 L/R CONTROL T20 20DG/BK 11 LINE PRESSURE CONTROL T118 20DG 12 GROUND Z133 18BK/LG 13 GROUND Z133 18BK/LG 14 GROUND Z133 18BK/LG 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 24 25 26 TRS T2 SIGNAL T4 20DG/LB 27 TRS T41 SIGNAL (P/N) T41 20YL/DB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 513 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 514 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 OD SOLENOID CONTROL T60 20YL/GY 2 4C CONTROL T259 20YL/DG 2 UD CONTROL T59 20YL/LB 3-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 515 4 MS CONTROL T140 20YL/GY 5-6 2C CONTROL T219 20YL/LG 6 2-4 SOLENOID CONTROL T19 18YL/DB 7-8 UD CONTROL T59 20YL/LB 9-10 L/R CONTROL T20 20DG/WT 11 PRESSURE CONTROL SOLENOID CONTROL T118 20DG 12 GROUND Z908 18BK 13 GROUND Z977 18BK 14 GROUND Z904 18BK 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 - 24 - 25 - 26 TRS T2 SIGNAL T4 20DG/LB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 30 2-4 PRESSURE SWITCH SENSE T47 18YL/DG 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 516 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 517 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 520 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 521 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 522 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 523 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 524 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 525 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 526 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 527 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 528 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 529 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 530 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 531 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 532 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 533 Engine Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 534 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 535 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 536 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 537 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 538 Engine Control Module: Connector Views Module-Engine Control Component ID: 203 Component : MODULE-ENGINE CONTROL Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (5.9L) Pin Description Circuit 1 WASTEGATE SOLENOID CONTROL K139 18DB 2 OIL PRESSURE SIGNAL G6 18VT/GY 3-4 CAN C BUS (+) D65 18WT/LG 5 CAN C BUS (-) D64 18WT/LB 6 FUEL CONTROL ACTUATOR RETURN K65 18BR/LB 7 GEN FIELD CONTROL K20 18BR/GY 8 TTVA MOTOR (+) K314 18TN/YL 9-10 - 11 WATER IN FUEL SENSOR GROUND K923 18BR/WT 12 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 13 INLET AIR TEMPERATURE SENSE K615 18VT/WT 14 - 15 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 16 INLET AIR PRESSURE SENSE K616 18BR/YL 17 ECT SIGNAL K2 18VT/OR 18 - 19 FUEL CONTROL ACTUATOR DRIVER K604 18BR/TN 20 TTVA MOTOR (-) K315 18TN/OR 21 FAN SPEED SENSOR GROUND K161 18BR/LB 22 CKP SIGNAL K24 18BR/LB 23 SENSOR GROUND K200 18BR/YL 24 CMP SIGNAL K44 18DB/GY 25 5 VOLT SUPPLY K668 18BR 26 - 27 5 VOLT SUPPLY K853 18DB/BR 28 - 29 SENSOR GROUND K690 18BR/YL 30 INJECTOR CONTROL NO. 1 K11 16BR/YL 31 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 539 32 CMP SENSOR GROUND K944 18BK/GY 33 APPS NO. 1 RETURN K167 18BR/YL 34 FAN SPEED SENSOR SIGNAL N210 18DB/DG 35 - 36 INJECTOR CONTROL NO. 4 K14 16BR/TN 37 - 38 - 39 - 40 INJECTOR CONTROL NO. 3 K13 16TN 41 SENSOR GROUND K210 18DB/TN 42 5 VOLT SUPPLY K852 18BR/VT 43 BOOST PRESSURE SENSOR SIGNAL K37 18LB 44 - 45 - 46 INJECTOR CONTROL NO. 6 K58 16BR/VT 47 - 48 - 49 - 50 INJECTOR CONTROL NO. 2 K12 16BR/DB 51 - 52 CKP SENSOR GROUND K975 18BR/OR 53 FUEL RAIL SENSOR RETURN K915 18BR/WT 54 5 VOLT SUPPLY F855 18PK/YL 55 - 56 INJECTOR CONTROL NO. 5 K38 16GY 57 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 16TN/PK 58 - 59 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 16BR/LG 60 - Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 540 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 541 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 542 Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 2 EGR CONTROL NO. 1 K682 18DB/WT 3 EGR CONTROL NO. 2 K684 18DB/YL 4 EGR CONTROL NO. 3 K686 18GY/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 543 5 EGR SIGNAL NO. 2 K685 18DB 6-7 FAN SPEED SENSOR GROUND K161 18BR/LB 8-9 EGR BYPASS VALVE SIGNAL K670 18BR/LB 10 FUEL CONTROL ACTUATOR RETURN K366 18BR/LB 11 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 12 - 13 EGR AIRFLOW CONTROL VALVE MOTOR (-) K314 18BR 14 CRANKCASE SENSOR SIGNAL K926 18DB/GY 15 ECT SIGNAL K2 18VT/OR 16 - 17 EGR BYPASS STATUS K671 18BR/DB 18 FAN SPEED SENSOR SIGNAL N27 18DB/GY 19 BOOST PRESSURE SENSOR SIGNAL K37 18BR 20 INLET AIR PRESSURE SENSE K616 18BR/YL 21 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 22 SENSOR GROUND K971 18BR/PK 23 - 24 INLET AIR TEMPERATURE SENSE K615 18VT/WT 25 EGR SIGNAL NO. 1 K683 18DB/GY 26 5 VOLT SUPPLY K824 18DB/BR 27 EGR AIRFLOW CONTROL VALVE MOTOR (+) K158 18BR/YL 28 GEN SENSE A804 18RD 29 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 30 FUEL CONTROL ACTUATOR DRIVER K365 18DB/BR 31 CKP SIGNAL K24 18BR/LB 32 OIL PRESSURE SIGNAL G6 18VT/GY 33 ACTUATOR GROUND K972 18DB/TN 34 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG 35 EGR SIGNAL NO. 3 K687 18DB/LB 36 5 VOLT SUPPLY F855 18PK/YL 37 CMP SIGNAL K44 18DB/GY 38 ACTUATOR HIGH DATA LINK D130 18BR/VT 39 ACTUATOR LOW DATA LINK D131 18WT/LG 40 GEN FIELD CONTROL K20 18BR/GY 41 EGR TEMPERATURE SENSOR SIGNAL K935 18DB 42 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 43 TURBO SPEED SENSOR GROUND K541 18BR/VT 44 CKP SENSOR GROUND K925 18BR/OR 45 INJECTOR CONTROL NO. 6 K58 16BR/VT 46 INJECTOR CONTROL NO. 2 K12 16BR/DB 47 SENSOR GROUND K914 18BR/WT 48 SENSOR GROUND K916 18BR/OR 49 - 50 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG 51 INJECTOR HIGH SIDE DRIVER NO. 3 K613 16GY/BR 52 INJECTOR HIGH SIDE DRIVER NO. 2 K612 16YL/BR 53 INJECTOR HIGH SIDE DRIVER NO. 1 K611 16OR/BR 54 INJECTOR CONTROL NO. 4 K14 16BR/TN 55 INJECTOR CONTROL NO. 5 K38 16GY 56 INJECTOR CONTROL NO. 3 K13 16TN 57 INJECTOR CONTROL NO. 1 K11 16BR/YL 58 INJECTOR HIGH SIDE DRIVER NO. 6 K658 16LG/BR 59 INJECTOR HIGH SIDE DRIVER NO. 5 K638 16LB/BR 60 INJECTOR HIGH SIDE DRIVER NO. 4 K614 16WT/BR Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 544 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 545 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 546 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 50 Qualifier : (5.9L) Pin Description Circuit 1-2-3 APPS NO. 1 SIGNAL K23 18BR/WT 4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 547 5 TRANSMISSION CONTROL T515 18YL/DB 6 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 7 FUEL PUMP CONTROL K31 18BR 8-9 TRS T41 SIGNAL (P/N) T41 18YL/DB 10 - 11 - 12 - 13 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 18DG 14 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 15 3-4 SOLENOID CONTROL T9 18DG/TN 16 - 17 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 18 - 19 - 20 FUSED B(+) A209 16RD 21 GROUND Z902 16BK 22 - 23 5 VOLT SUPPLY F856 18YL/PK 24 SENSOR GROUND K900 18DB/DG 25 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 26 - 27 TTVA POSITION SENSOR SIGNAL K312 18OR 28 - 29 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR 30 FUSED B(+) A209 16RD 31 - 32 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 33 5 VOLT SUPPLY K854 18VT/BR 34 - 35 APPS NO. 2 SIGNAL K29 18WT/BR 36 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 37 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 38 - 39 - 40 FUSED B(+) A209 16RD 41 A/C CLUTCH CONTROL C13 18LB/OR 42 - 43 PWM FAN COIL SIGNAL K160 18BR/OR 44 OUTPUT SPEED SIGNAL T14 18DG/BR 45 SPEED SENSOR GROUND T13 18DG/VT 46 S/C SWITCH NO. 1 SIGNAL V37 18VT 47 BATT TEMP SIGNAL K25 18DB/VT 48 APPS NO. 2 RETURN K400 18BR/VT 49 GROUND Z902 16BK 50 GROUND Z902 16BK Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 548 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 549 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 550 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 CAN C BUS (+) D65 18WT/LG 2 FUEL PUMP CONTROL K31 18BR 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 551 5 EXHAUST BRAKE SWITCH SIGNAL G905 18BR/OR 6 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 7 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 8 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 9 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/OR 10 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 11 - 12 - 13 - 14 - 15 CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT T26 18DG/OR 16 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 17 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 18 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 19 - 20 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 21 CAN C BUS (-) D64 18WT/LB 22 APPS NO. 2 RETURN K400 18BR/VT 23 - 24 APPS NO. 2 SIGNAL K29 18WT/BR 25 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 26 5 VOLT SUPPLY K854 18VT/BR 27 5 VOLT SUPPLY K852 18BR/LB 28 APPS NO. 1 RETURN K167 18BR/DG 29 SENSOR GROUND K900 18DB/DG 30 BATT TEMP SIGNAL K25 18DB/VT 31 DIAGNOSTIC PORT HIGH DATA LINK D133 18WT/OR 32 - 33 S/C SWITCH RETURN V937 18VT/BR 34 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 35 APPS NO. 1 SIGNAL K23 18BR/WT 36 - - 37 REMOTE THROTTLE SIGNAL K128 18DG/LG 38 - 39 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 40 S/C SWITCH NO. 1 SIGNAL V37 18VT 41 - 42 - 43 SMART POWER RELAY RETURN K348 18BR 44 A/C CLUTCH CONTROL C13 18LB 45 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 46 - 47 GROUND Z902 16BK 48 GROUND Z902 16BK 49 FUSED B(+) A209 16RD 50 FUSED B(+) A209 16RD 51 DIAGNOSTIC PORT LOW DATA LINK D132 18WT 52 - 53 - 54 EXHAUST BRAKE LAMP SIGNAL G904 18VT/DG 55 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 56 S/C SWITCH NO. 2 SIGNAL V38 18VT/OR 57 GROUND Z902 16BK 58 - 59 - 60 FUSED B(+) A209 16RD Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 552 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 553 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 554 Module-Powertrain Control Component ID: 209 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 555 Pin Description Circuit 123456789-10 11 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (RUN-START) F1 20PK/WT 13 14 15 16 17 18 - 19 SENSOR GROUND T160 20DG/WT 20 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 21 22 23 24 25 26 - 27 5 VOLT SUPPLY F856 20YL/PK 28 29 FUSED B(+) A918 20RD 30 IGNITION START T751 20YL 31 - 32 33 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 38 Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 556 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 557 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 8 K98 18DB/YL 2-3 COIL CONTROL NO. 7 K97 18DB/YL 3 COIL CONTROL NO. 7 K97 18BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 558 4 INJECTOR CONTROL NO. 8 K28 18BR/LB 5 INJECTOR CONTROL NO. 7 K26 18BR/YL 6-7-8-9 GROUND Z130 16BK/BR 10 FUSED B(+) A918 16RD 11 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 13 - 14 - 15 - 16 - 17 - 18 GROUND Z131 16BK/DG 19 GROUND Z951 16BK/YL 20 OIL PRESSURE SIGNAL G6 16VT/GY 21 - 22 - 23 - 24 GEN SENSE A804 18RD/GY 25 - 27 5 VOLT SUPPLY F856 20YL/PK 28 MDS SOL CONTROL NO. 4 K452 20BR/LB 29 FUSED B(+) A918 16RD 30 IGNITION START T751 20YL 31 O2 1/2 SIGNAL K141 20DB/YL 32 O2 1/1 RETURN K902 20BR/DG 33 O2 2/2 SIGNAL K243 20BR 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 - - 38 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 559 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 560 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 6 K10 18DB/OR 2 COIL CONTROL NO. 5 K16 18DB/YL 3 COIL CONTROL NO. 4 K15 18DB/GY 4 INJECTOR CONTROL NO. 6 K58 18BR/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 561 5 INJECTOR CONTROL NO. 5 K38 18BR/OR 6 ETC MOTOR (+) K447 20TN/YL 7 COIL CONTROL NO. 3 K18 18DB/OR 8 EGR SOL CONTROL K35 20DB/VT 9 COIL CONTROL NO. 2 K17 18DB/TN 10 COIL CONTROL NO. 1 K19 18DB/DG 11 INJECTOR CONTROL NO. 4 K14 18BR/TN 12 INJECTOR CONTROL NO. 3 K13 18BR/LB 13 INJECTOR CONTROL NO. 2 K12 18BR/DB 14 INJECTOR CONTROL NO. 1 K11 18BR/YL 15 TP SENSOR RETURN K922 20BR/DB 16 MDS SOL CONTROL NO. 6 K453 20BR/DG 17 O2 2/1 HEATER CONTROL K199 20BR/VT 18 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 19 GEN FIELD CONTROL K20 18BR/GY 20 ECT SIGNAL K2 20VT/OR 21 TP NO. 1 SIGNAL K22 20BR/OR 22 EGR SIGNAL K34 20DB/LG 23 MAP SIGNAL K1 20VT/BR 24 KNOCK SENSOR NO. 1 RETURN K942 20BR/LG 25 KNOCK SENSOR NO. 1 SIGNAL K42 20DB/YL 26 - 27 SENSOR GROUND K900 20DB/DG 28 TP NO. 2 SIGNAL K122 20BR/DG 28 IAC SIGNAL K961 20BR/VT 29 5 VOLT SUPPLY F855 20PK/YL 30 IAT SIGNAL K21 20DB/LG 31 O2 1/1 SIGNAL K41 20DB/LB 32 O2 1/2 RETURN K904 20DB/DG 33 O2 2/1 SIGNAL K43 20DB/LG 34 CMP SIGNAL K44 20DB/GY 35 CKP SIGNAL K24 20BR/LB 36 KNOCK SENSOR NO. 2 SIGNAL K242 20BR/WT 37 KNOCK SENSOR NO. 2 RETURN K924 20WT/BR 38 ETC MOTOR (-) K448 20TN/OR 38 IAC CONTROL K61 20VT/GY Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 562 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 563 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1-2-3 ASD CONTROL K51 20BR/WT 4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 564 5 S/C VENT SOL CONTROL V35 20VT/OR 5 MDS SOL CONTROL NO. 7 K454 20BR/OR 6 MDS SOL CONTROL NO. 1 K451 20BR/WT 7 SPEED CONTROL SUPPLY V32 20VT/YL 8-9 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 10 O2 2/2 HEATER CONTROL K399 18BR/GY 11 A/C CLUTCH CONTROL C13 20LB/OR 12 S/C VACUUM SOL CONTROL V36 20VT/YL 13 - 14 BRAKE SWITCH NO. 2 SIGNAL V32 20VT/YL 15 S/C SWITCH RETURN V937 20VT/BR 16 APPS NO. 1 RETURN K167 20BR/YL 17 APPS NO. 2 RETURN K400 20BR/VT 18 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 19 ASD CONTROL OUTPUT K342 16BR/WT 20 EVAP PURGE SOL CONTROL K52 20DB/WT 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 PTO SENSE G113 20VT 22 PTO SENSE G113 18PK/YL 23 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT 24 - 25 APPS NO. 1 SIGNAL K23 20BR/WT 26 - 27 - 28 ASD CONTROL OUTPUT K342 16BR/WT 29 EVAP PURGE SOL SIGNAL K70 20DB/BR 30 P/S SWITCH SIGNAL K66 20DB/WT 31 - 32 - 33 OIL TEMPERATURE SIGNAL G24 20VT/BR 34 S/C SWITCH NO. 1 SIGNAL V37 20VT 35 ESM SIGNAL K107 20VT/WT 36 APPS NO. 2 SIGNAL K29 20WT/BR 37 FUEL PUMP CONTROL K31 20BR 38 STARTER SOLENOID CONTROL T752 20DG/OR Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 565 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 566 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Description Circuit 1 SENSOR GROUND T160 20YL/GY 2 4C CONTROL T259 20YL/DG 34 MS CONTROL T140 20YL/GY Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 567 5- 6 2C CONTROL T219 20YL/LG 78 UD CONTROL T59 20YL/LB 910 L/R CONTROL T20 20DG/BK 11 LINE PRESSURE CONTROL T118 20DG 12 GROUND Z133 18BK/LG 13 GROUND Z133 18BK/LG 14 GROUND Z133 18BK/LG 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 24 25 26 TRS T2 SIGNAL T4 20DG/LB 27 TRS T41 SIGNAL (P/N) T41 20YL/DB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 568 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 569 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 OD SOLENOID CONTROL T60 20YL/GY 2 4C CONTROL T259 20YL/DG 2 UD CONTROL T59 20YL/LB 3-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 570 4 MS CONTROL T140 20YL/GY 5-6 2C CONTROL T219 20YL/LG 6 2-4 SOLENOID CONTROL T19 18YL/DB 7-8 UD CONTROL T59 20YL/LB 9-10 L/R CONTROL T20 20DG/WT 11 PRESSURE CONTROL SOLENOID CONTROL T118 20DG 12 GROUND Z908 18BK 13 GROUND Z977 18BK 14 GROUND Z904 18BK 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 - 24 - 25 - 26 TRS T2 SIGNAL T4 20DG/LB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 30 2-4 PRESSURE SWITCH SENSE T47 18YL/DG 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 571 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 572 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description Engine Control Module: Description and Operation Description DESCRIPTION CUMMINS FUEL SYSTEM COMPONENTS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 575 The Engine Control Module (ECM) for the 5.9L diesel engine (16) is bolted to the left side of the engine below the intake manifold. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 576 Engine Control Module: Description and Operation Operation OPERATION The main function of the Engine Control Module (ECM) is to electrically control the fuel system. The ECM also controls certain transmission and other functions previously controlled by the Powertrain Control Module (PCM). The ECM can adapt its programming to meet changing operating conditions. The ECM receives input signals from various switches and sensors. Based on these inputs, the ECM regulates various engine and vehicle operations through different system components. These components are referred to as ECM Outputs. The sensors and switches that provide inputs to the ECM are considered ECM Inputs. NOTE: ECM Inputs: - Accelerator Pedal Position Sensor (APPS) Signals #1 and #2 - AC system pressure - Auto shutdown (ASD) sense - Battery temperature - Battery temperature sensor - Battery voltage - Brake switch - Camshaft Position Sensor (CMP) - Crankshaft Position Sensor (CKP) - Data link connection for a scan tool - Engine Coolant Temperature (ECT) sensor - EATX module (if equipped) - Fuel level - Fuel pressure sensor - Fan speed (engine cooling fan) - Generator (battery voltage) output - Governor pressure (Auto. trans.) - Ground circuits - Inlet air temperature sensor/pressure sensor - Intake air temperature sensor/MAP sensor - CAN C BUS (+) circuits - CAN C BUS (-) circuits - Key switch (ignition) - Oil Pressure switch - Overdrive switch (automatic transmission only) - Park/neutral switch (auto. trans. only) - Power ground - SCI datalink bus (+) circuits - SCI datalink bus (-) circuits - Sensor return - Signal ground - Speed control multiplexed single wire input - Transfer case switch (4WD range position) - Transmission governor psi (automatic transmission only) - Transmission OSS (automatic transmission only) - Transmission oil pressure (automatic transmission only) - Transmission oil temperature (automatic transmission only) - Transmission throttle valve position (automatic transmission only) - Vehicle speed signal - Water-In-Fuel (WIF) sensor NOTE: ECM Outputs: After inputs are received by the ECM, certain sensors, switches and components are controlled or regulated by the ECM. These are considered ECM Outputs. These outputs are for: - A/C clutch relay - Auto shutdown (ASD) relay - Data link connection for diagnostic scan tool - Fan clutch PWM Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 577 - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel control actuator - Fuel injector driver circuits - Fuel transfer (lift) pump - Generator field driver (-) - Generator field driver (+) - Governor pressure (VFS solenoid) - Intake manifold air heater relays #1 and #2 control circuits - CAN C BUS (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oil pressure switch/warning lamp (databus) - Overdrive/3-4 shift solenoid (automatic transmission only) - SC source - SCI datalink bus (+) circuits - SCI datalink bus (-) circuits - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - TCC solenoid (automatic transmission only) - Transmission battery relay (automatic transmission only) - Transmission throttle valve actuator (automatic transmission only) - Transmission governor solenoid (automatic transmission only) - Wait-to-start warning lamp (databus) - Turbo wastegate solenoid - Water-In-Fuel (WIF) warning lamp (databus) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming Engine Control Module: Testing and Inspection PCM/ECM Programming PCM/ECM REPROGRAMMING MODULE REPROGRAMING Replacement PCM's will require programming utilizing the StarSCAN(R) or equivalent. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. SPECIAL TOOLS/EQUIPMENT OR EQUIVALENT REQUIRED: **REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The StarSCAN(R) or equivalent diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) or equivalent for your dealership's network. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9410 StarSCAN(R) or equivalent ethernet cable to the StarSCAN(R) or equivalent and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 4. Power ON the StarSCAN(R) or equivalent. 5. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. 6. Replace the PCM with the appropriate Generic PCM. 7. Program the PCM as follows: a. Using the StarSCAN(R) or equivalent at the "Home" screen, Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File". Follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 580 f. Highlight the appropriate calibration based on the part number recorded in Step 5. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. 8. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 9. b. No >> go to STEP 10. 9. Program the PCM to the Wireless Control Module (WCM). a. Highlight the WCM. b. Select "Misc. Function". c. Highlight "PCM Replaced". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step. f. When complete proceed to STEP 11. 10. Program the VIN into the PCM. a. Scroll through the list of controllers and highlight the PCM. b. Select "Misc. Function". c. Highlight "Check PCM VIN". d. Select "Start". e. Follow the on screen instructions. Select "Next" after each step . When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 11. Is the vehicle equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 13. b. No >> go to STEP 12. 12. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select ECU View b. Scroll through the list of controllers and highlight the PCM. c. Select Misc. Function. d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select Next after each step . Select Finish after completing the last step. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the Home screen select System View. Then select All DTCs. Press Clear All Stored DTCs if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label . REPAIR PROCEDURE USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 581 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 3. Power ON the StarSCAN(R) or equivalent. 4. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. 5. Replace the PCM with the appropriate Generic PCM. 6. Insert the StarSCAN(R) or equivalent Software Update CD into the Techconnect or equivalent PC. The StarSCAN(R) or equivalent Software Update CD will start automatically. Select "Download Flash Updates". 7. At the "Select a method for looking up controller flash updates." screen: a. Select "Enter part number". Enter the "Part Number" recorded in STEP 4 when prompted to do so. b. Using the mouse highlight the appropriate "Calibration". Select "Next". c. Follow the on screen instructions. d. When completed, proceed to STEP 8. 8. With the StarSCAN(R) or equivalent powered OFF, connect the USB Key and Gender Changer to the StarSCAN(R) or equivalent USB port . 9. Connect the StarSCAN(R) or equivalent to the vehicle (if not already connected). 10. Power ON the StarSCAN(R) or equivalent. 11. Download the flash file from the USB key to the StarSCAN(R) or equivalent. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "Flash Download", then select "Retrieve files from the USB storage device" b. Highlight the appropriate calibration. Select "Download to Scan Tool" c. When the download is complete, select "Close" and "Back". 12. Reprogram the ECU. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View". b. Select More Options". c. Select "ECU Flash". d. Highlight the appropriate calibration. e. Select "Update Controller". Follow the on screen instructions. f. When the update is complete, select "OK". g. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 582 13. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 14. b. No >> go to STEP 15. 14. Program the PCM to the Wireless Control Module (WCM). Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the WCM. c. Select "Misc. Function". d. Highlight "PCM Replaced". e. Select "Start". f. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step. g. When complete proceed to STEP 16. 15. Program the VIN into the PCM. a. Scroll through the list of controllers and highlight the PCM. b. Select "Misc. Function". c. Highlight "Check PCM VIN". d. Select "Start". e. Follow the on screen instructions. Select "Next" after each step . When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 16. Is the vehicle equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 18. b. No >> go to STEP 17. 17. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the PCM. c. Select "Misc. Function". d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "ECU View" from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 18. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label . Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 583 Engine Control Module: Testing and Inspection SKREEM Programming SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: 1. Program the new PCM/ECM. 2. Program the new SKREEM/WCM. 3. Replace all ignition keys and program them into the new SKREEM/WCM. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Be certain to enter the correct country code for the SKREEM/WCM. If the incorrect country code is programmed into the SKREEM, it cannot be changed and the SKREEM must be replaced. NOTE: In addition, the SKREEM/WCM must be configured for certain optional equipment in the vehicle, including Tire Pressure Monitor (TPM), Remote Keyless Entry (RKE) and Remote Start. Follow the programming steps outlined in the diagnostic scan tool under MISCELLANEOUS FUNCTIONS for the WCM/WIRELESS CONTROL MODULE menu item as appropriate. NOTE: A replacement SKREEM/WCM is supplied with TPM enabled by default; therefore, if the vehicle is not equipped with TPM, the ElectroMechanical Instrument Cluster (EMIC) will incorrectly learn that the vehicle has TPM after the replacement SKREEM is installed. The TPM indicator in the EMIC will illuminate to show a TPM fault condition after TPM has been disabled in the SKREEM. The EMIC must unlearn TPM to correct this false TPM indication. Follow the programming steps outlined in the diagnostic scan tool for CLEAR LEARNED FEATURES under MISCELLANEOUS FUNCTIONS for the INSTRUMENT CLUSTER menu item as appropriate. NOTE: If the PCM/ECM and the SKREEM/WCM are replaced at the same time, all vehicle ignition keys will need to be replaced and the new keys programmed into the new SKREEM/WCM. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 584 Engine Control Module: Testing and Inspection Programming The SKREEM/WCM Using The Scan Tool STANDARD PROCEDURE - PROGRAMMING THE SKREEM/WCM USING THE SCAN TOOL CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the scan tool. CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal Engine Control Module: Service and Repair Removal 6.7L DIESEL The Engine Control Module (ECM) (5) is located on the left side of the engine. A support bracket mounts to the block with four capscrews and vibration isolators. A ground wire is fastened to the bracket. The other end of the wire is fastened to the engine block. 1. Record any Diagnostic Trouble Codes (DTC's) found in the ECM. To avoid possible voltage spike damage to the ECM, ignition key must be off, and both negative battery cables must be disconnected before unplugging ECM connectors. 2. Disconnect both negative battery cables at both batteries. Access to the ECM is easier by working through the left front wheel opening. 3. Remove left front wheel. 4. Remove plastic left front fender splash shield. 5. Remove electrical connector bolts at ECM. Note: As each bolt is being removed, very carefully remove connectors from the ECM. 6. Remove three ECM mounting bolts (6) and remove ECM from engine. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 587 Engine Control Module: Service and Repair Installation 6.7L DIESEL Do not apply paint to ECM or a poor ground will result. 1. Position ECM (5) to the ECM support bracket and install mounting bolts. Tighten bolts to 24 Nm (18 ft. lbs.). 2. Check pins in electrical connectors for corrosion, damage or dirt intrusion. Also check all pins for being bent. Repair as necessary. Damaged, dirty, bent or corroded pins could result in poor conductivity, causing intermittent electrical issues or DTC's. 3. Clean pins in electrical connectors with an electrical contact cleaner. 4. Install connectors to ECM. Tighten connector bolts to 3 Nm (27 in. lbs.). 5. Install splash shield. 6. Install left front wheel. 7. Connect both negative battery cables. 8. Use a diagnostic scan tool to erase any Diagnostic Trouble Codes (DTC's) from ECM. FUEL INJECTOR ID CORRECTION CODES: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 588 Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector (1) and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Engine Control Module (ECM) using a diagnostic scan tool. In addition, if a new ECM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new ECM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 592 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 593 Main Relay (Computer/Fuel System): Diagrams Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 594 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 595 Main Relay (Computer/Fuel System): Testing and Inspection Fig.1 ASD And Fuel Pump Relay Terminals-Type 1 Fig.2 ASD And Fuel Pump Relay Terminals-Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 596 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Diagrams Oxygen Sensor Relay: Diagrams 2007-2009 Ram truck, 6.7L, use an O2 module for oxygen sensor heater control. The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 604 8w-30-17 Connector C1 pin 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 607 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 608 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 609 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 610 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 611 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 612 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 613 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 614 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 615 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 616 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 617 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 618 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 619 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 620 Fuel Pump Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 621 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 622 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 623 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 624 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 625 Fuel Pump Relay: Connector Views Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 626 Fuel Pump Relay: Description and Operation The fuel transfer pump (fuel lift pump) is part of the fuel pump module. The fuel pump module is located in the fuel tank. The 12-volt electric pump is operated and controlled by the Engine Control Module (ECM). The ECM controls a relay in the intelligent Power Module (IPM) for transfer pump operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations Intake Air Heater Relay: Locations Component ID: 240 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 FUSED B(+) A19 10DG 30 FUSED B(+) A19 10RD/YL 85 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 86 GROUND Z174 18BK 86 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 87 INTAKE AIR HEATER RELAY OUTPUT A58 4BK Component Location - 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Page 630 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Page 631 Intake Air Heater Relay: Diagrams Component ID: 240 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 FUSED B(+) A19 10DG 30 FUSED B(+) A19 10RD/YL 85 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 86 GROUND Z174 18BK 86 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 87 INTAKE AIR HEATER RELAY OUTPUT A58 4BK Component Location - 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Page 632 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Page 633 Intake Air Heater Relay: Description and Operation OPERATION The Engine Control Module (ECM) operates the heating element through the intake manifold air heater relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Service and Repair > Removal Intake Air Heater Relay: Service and Repair Removal REMOVAL The intake manifold air heater relay (5) is located in the engine compartment. It attached to a bracket. This bracket is attached to the right battery tray (3). The mounting bracket and relay is replaced as an assembly. 1. Disconnect both negative battery cables at both batteries. 2. Disconnect relay trigger wires (4) at relays. Note position of wiring before removing. 3. Remove nuts (2) at cable connectors and disconnect cables (1) from mounting studs. Note position of cables before removing. 4. Remove two relay mounting bracket screws (6) and remove relay assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Service and Repair > Removal > Page 636 Intake Air Heater Relay: Service and Repair Installation INSTALLATION The intake manifold air heater relay (5) is located in the engine compartment. It attached to a bracket. This bracket is attached to the right battery tray (3). The mounting bracket and relay is replaced as an assembly. 1. Position relay and install two relay mounting bracket screws (6). 2. Position cables (1) to mounting studs and install nuts (2). 3. Connect relay trigger wires (4) at relays. 4. Connect both negative battery cables to both batteries. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 640 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 641 Main Relay (Computer/Fuel System): Diagrams Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 642 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 643 Main Relay (Computer/Fuel System): Testing and Inspection Fig.1 ASD And Fuel Pump Relay Terminals-Type 1 Fig.2 ASD And Fuel Pump Relay Terminals-Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 644 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Component ID: 208 Component : MODULE-OCCUPANT RESTRAINT CONTROLLER Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C1 Color : YELLOW # of pins : 24 Pin Description Circuit 1-2-3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT 5-6 PASSENGER AIRBAG INDICATOR DRIVER G104 20VT/GY 7 PASSENGER AIRBAG MUX SWITCH RETURN R104 20LB/LG 8 PASSENGER AIRBAG MUX SWITCH SENSE R106 20LG/LB 9 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 10 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT 11 RIGHT FRONT IMPACT SENSOR GROUND R82 20WT/LB 12 RIGHT FRONT IMPACT SENSOR SIGNAL R80 20VT/LB 13 - 14 - 15 - 16 - 17 DRIVER SQUIB 1 LINE 1 R43 20LG/BR 18 DRIVER SQUIB 1 LINE 2 R45 20LG/OR 19 PASSENGER SQUIB 1 LINE 2 R44 20LB/OR 20 PASSENGER SQUIB 1 LINE 1 R42 20LB/BR 21 DRIVER SQUIB 2 LINE 1 R61 20LG/VT 22 DRIVER SQUIB 2 LINE 2 R63 20LG/WT 23 PASSENGER SQUIB 2 LINE 1 R64 20LB/WT 24 PASSENGER SQUIB 2 LINE 2 R62 20LB/VT Component Location - 58 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 649 Component Location - 63 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 650 Component Location - 51 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 651 Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C2 Color : YELLOW # of pins : 32 Pin Description Circuit 1 RIGHT CURTAIN SQUIB 1 LINE 2 R2 20WT/LB 2 RIGHT CURTAIN SQUIB 1 LINE 1 R4 20OR/LB 3 LEFT CURTAIN SQUIB 1 LINE 1 R3 20LB/OR 4 LEFT CURTAIN SQUIB 1 LINE 2 R1 20LB/WT 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 652 6-7-8-9 DRIVER SEAT BELT TENSIONER LINE 2 R53 20LG/YL 10 DRIVER SEAT BELT TENSIONER LINE 1 R55 20LG/DG 11 PASSENGER SEAT BELT TENSIONER LINE 1R56 20LB/DG 12 PASSENGER SEAT BELT TENSIONER LINE 2R54 20LB/YL 13 LEFT CURTAIN SQUIB 1 LINE 2 R1 20LB/WT 14 LEFT CURTAIN SQUIB 1 LINE 1 R3 20LB/OR 15 RIGHT CURTAIN SQUIB 1 LINE 1 R4 20OR/LB 16 RIGHT CURTAIN SQUIB 1 LINE 2 R2 20WT/LB 17 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 18 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20PK/VT 19 - 20 GROUND Z104 18BK/LG 21 - 22 - 23 - 24 - 25 DRIVER SEAT POSITION SENSOR DATA R261 20LB/TN 26 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/GY 27 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 28 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 29 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 30 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 31 - 32 - Component Location - 58 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 653 Component Location - 63 Component Location - 51 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 654 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 655 Air Bag Control Module: Diagrams Component ID: 208 Component : MODULE-OCCUPANT RESTRAINT CONTROLLER Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C1 Color : YELLOW # of pins : 24 Pin Description Circuit 1-2-3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT 5-6 PASSENGER AIRBAG INDICATOR DRIVER G104 20VT/GY 7 PASSENGER AIRBAG MUX SWITCH RETURN R104 20LB/LG 8 PASSENGER AIRBAG MUX SWITCH SENSE R106 20LG/LB 9 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 10 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT 11 RIGHT FRONT IMPACT SENSOR GROUND R82 20WT/LB 12 RIGHT FRONT IMPACT SENSOR SIGNAL R80 20VT/LB 13 - 14 - 15 - 16 - 17 DRIVER SQUIB 1 LINE 1 R43 20LG/BR 18 DRIVER SQUIB 1 LINE 2 R45 20LG/OR 19 PASSENGER SQUIB 1 LINE 2 R44 20LB/OR 20 PASSENGER SQUIB 1 LINE 1 R42 20LB/BR 21 DRIVER SQUIB 2 LINE 1 R61 20LG/VT 22 DRIVER SQUIB 2 LINE 2 R63 20LG/WT 23 PASSENGER SQUIB 2 LINE 1 R64 20LB/WT 24 PASSENGER SQUIB 2 LINE 2 R62 20LB/VT Component Location - 58 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 656 Component Location - 63 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 657 Component Location - 51 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 658 Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C2 Color : YELLOW # of pins : 32 Pin Description Circuit 1 RIGHT CURTAIN SQUIB 1 LINE 2 R2 20WT/LB 2 RIGHT CURTAIN SQUIB 1 LINE 1 R4 20OR/LB 3 LEFT CURTAIN SQUIB 1 LINE 1 R3 20LB/OR 4 LEFT CURTAIN SQUIB 1 LINE 2 R1 20LB/WT 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 659 6-7-8-9 DRIVER SEAT BELT TENSIONER LINE 2 R53 20LG/YL 10 DRIVER SEAT BELT TENSIONER LINE 1 R55 20LG/DG 11 PASSENGER SEAT BELT TENSIONER LINE 1R56 20LB/DG 12 PASSENGER SEAT BELT TENSIONER LINE 2R54 20LB/YL 13 LEFT CURTAIN SQUIB 1 LINE 2 R1 20LB/WT 14 LEFT CURTAIN SQUIB 1 LINE 1 R3 20LB/OR 15 RIGHT CURTAIN SQUIB 1 LINE 1 R4 20OR/LB 16 RIGHT CURTAIN SQUIB 1 LINE 2 R2 20WT/LB 17 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 18 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20PK/VT 19 - 20 GROUND Z104 18BK/LG 21 - 22 - 23 - 24 - 25 DRIVER SEAT POSITION SENSOR DATA R261 20LB/TN 26 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/GY 27 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 28 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 29 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 30 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 31 - 32 - Component Location - 58 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 660 Component Location - 63 Component Location - 51 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 661 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Description Air Bag Control Module: Description and Operation Description DESCRIPTION The Occupant Restraint Controller (ORC) (1) is located in the passenger compartment of the vehicle, where it is secured by three nuts to three studs on a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel under the center front seat or the center floor console, as the vehicle is equipped. Concealed within a hollow in the center of the die cast aluminum ORC housing is the electronic circuitry of the ORC which includes a microprocessor, an electronic impact sensor, an electronic safing sensor, and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ORC housing with screws to enclose and protect the internal electronic circuitry and components. An arrow (2) printed on the label (3) on the top of the ORC housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ORC housing has integral mounting flanges on three corners. The mounting flange to the right of the connector receptacles (4) has an integral locating pin on its lower surface. Both right side flanges have round mounting holes, while the flange on the left side has a slotted mounting hole. A molded plastic electrical connector (4) with 2 receptacles, one containing 24 terminal pins and the other containing 32 terminal pins, exits the forward facing side of the ORC housing. These terminal pins connect the ORC to the vehicle electrical system through two dedicated take outs and connectors, one each from the instrument panel and the body wire harnesses. A molded plastic protective cover is installed over the ORC to provide additional moisture contamination protection to the unit. Integral latch features on each side of the cover engage a slot (5) on each side of the base of the ORC housing to secure the cover to the ORC. This protective cover must be reinstalled following any service requiring its removal. The impact sensor and safing sensor internal to the ORC are calibrated for the specific vehicle, and are only serviced as a unit with the ORC. In addition, there are unique versions of the ORC for light and heavy-duty vehicles, and for vehicles with or without the optional side curtain airbags. The ORC cannot be repaired or adjusted and, if damaged or ineffective, it must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Description > Page 664 Air Bag Control Module: Description and Operation Operation OPERATION The microprocessor in the Occupant Restraint Controller (ORC) contains the supplemental restraint system logic circuits and controls all of the supplemental restraint system components. The ORC uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Controller Area Network (CAN) data bus. This method of communication is used for control of the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) and for supplemental restraint system diagnosis and testing through the 16-way Data Link Connector (DLC) located on the driver side lower edge of the instrument panel. The ORC microprocessor continuously monitors all of the supplemental restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC over the CAN data bus to turn ON the airbag indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the ORC. For some DTCs, if a fault does not recur for a number of ignition cycles, the ORC will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. In standard cab vehicles, the ORC also monitors a resistor multiplexed input from the passenger airbag on/off switch. If the passenger airbag on/off switch is set to the OFF position, the ORC turns ON the passenger airbag on/off indicator and will internally disable the passenger airbag and seat belt tensioner from being deployed. The ORC receives battery current through two circuits; a fused ignition switch output (run) circuit through a fuse in the Totally Integrated Power Module (TIPM), and a fused ignition switch output (run-start) circuit through a second fuse in the TIPM. The ORC receives ground through a ground circuit and take out of the instrument panel wire harness. This take out has a single eyelet terminal connector that is secured by a ground screw to the instrument panel structural support. These connections allow the ORC to be operational whenever the ignition switch is in the START or ON positions. The ORC also contains an energy-storage capacitor. When the ignition switch is in the START or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the supplemental restraint components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup supplemental restraint system protection in case there is a loss of battery current supply to the ORC during an impact. Two sensors are contained within the ORC, an electronic impact sensor and a safing sensor. The ORC also monitors inputs from two remote front impact sensors located on the back of the right and left ends of the lower radiator crossmember near the front of the vehicle. The electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provide verification of the direction and severity of an impact. On vehicles equipped with optional side curtain airbags the ORC also monitors inputs from two additional remote impact sensors located within both the left and right B-pillars to control deployment of the side curtain airbag units. The safing sensor is an electronic accelerometer sensor within the ORC that provides an additional logic input to the ORC microprocessor. The safing sensor is used to verify the need for a supplemental restraint deployment by detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags to deploy. Vehicles equipped with optional side curtain airbags feature a second safing sensor within the ORC to provide confirmation to the ORC microprocessor of side impact forces. This second safing sensor is a bi-directional unit that detects impact forces from either side of the vehicle. Pre-programmed decision algorithms in the ORC microprocessor determine when the deceleration rate as signaled by the impact sensors and the safing sensors indicate an impact that is severe enough to require supplemental restraint system protection and, based upon the severity of the monitored impact, determines the level of front airbag deployment force required for each front seating position. When the programmed conditions are met, the ORC sends the proper electrical signals to deploy the dual multistage front airbags at the programmed force levels, the front seat belt tensioners and, if the vehicle is so equipped, either side curtain airbag unit. On standard cab vehicles, the passenger front airbag and seat belt tensioner will be deployed by the ORC only if enabled by the passenger airbag on/off switch at the time of the impact. The hard wired inputs and outputs for the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ORC or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the ORC or the electronic controls and communication related to ORC operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal Air Bag Control Module: Service and Repair Removal Module MODULE WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the occupant restraint controller, as it can damage the impact sensor or affect its calibration. The occupant restraint controller contains the impact sensor, which enables the system to deploy the supplemental restraints. If an occupant restraint controller is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the protective cover from the Occupant Restraint Controller (ORC) (1). 3. Unlatch and disconnect the two wire harness connectors (3) for the ORC from the ORC connector receptacles (2 and 4) located on the forward facing side of the module. To disconnect the wire harness connectors from the ORC, depress the release tab and lift the lever arm on each connector. 4. Remove the three nuts (2) that secure the ORC (1) to the studs on the ORC mounting bracket (3) on the floor panel transmission tunnel. 5. Remove the ORC from the floor panel transmission tunnel. Cover Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal > Page 667 COVER WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. NOTE: The front seat assembly must be unfastened from the floor panel, but need not be removed from the vehicle for access to the Occupant Restraint Controller (ORC) cover for service. 2. Remove the front seat from the vehicle. 3. Using a trim stick or another suitable wide flat-bladed tool, gently pry the latch feature on either side of the ORC cover (1) away from the base of the ORC (2) far enough to disengage the cover from the module. 4. Remove the ORC cover from over the ORC. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal > Page 668 Air Bag Control Module: Service and Repair Installation Module MODULE WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the occupant restraint controller, as it can damage the impact sensor or affect its calibration. The occupant restraint controller contains the impact sensor, which enables the system to deploy the supplemental restraints. If an occupant restraint controller is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. 1. Position the Occupant Restraint Controller (ORC) (1) over the three studs of the ORC mounting bracket (3) on the floor panel transmission tunnel, then engage the locating pin on the bottom of the right ORC mounting flange into the locating hole in the bracket. When the ORC is correctly positioned, the arrow on the ORC label will be pointed forward in the vehicle. 2. Install and tighten the three nuts (2) that secure the ORC to the bracket on the floor panel transmission tunnel. Tighten the nuts to 10 Nm (7 ft. lbs.). 3. Reconnect the two wire harness connectors (3) for the ORC (1) to the ORC connector receptacles (2 and 4) located on the forward facing side of the module. Be certain that the latches on the connectors are each fully engaged. 4. Reinstall the ORC cover onto the ORC. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal > Page 669 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Cover COVER WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the ORC cover (1) over the Occupant Restraint Controller (ORC) (2). 2. Align the latch feature on each side of the ORC cover with the notch in each side at the base of the ORC housing. 3. Using hand pressure, press firmly and evenly downward on the ORC cover until each latch feature is fully engaged with the ORC housing. 4. Reinstall the front seat into the vehicle. 5. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams Relay - Starter Motor (Except SRT) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations Steering Mounted Controls Communication Module: Locations Component ID: 212 Component : MODULE-STEERING CONTROL Connector: Name : MODULE-STEERING CONTROL C1 Color : WHITE # of pins : 6 Pin Description Circuit 1 GROUND Z909 20BK 2 RADIO CONTROL MUX X20 20GY/WT 3 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 4 S/C SWITCH NO. 1 SIGNAL V37 20VT 5 S/C SWITCH RETURN V937 20VT/BR 6 HORN SWITCH SENSE X3 20DG/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 679 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 680 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 681 Connector: Name : MODULE-STEERING CONTROL C2 Color : BLACK # of pins : 2 Qualifier : (PREMIUM) Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 682 2 RADIO CONTROL MUX X20 22GY/WT 2 RADIO CONTROL MUX X20 22GY/WT Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 683 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 684 Connector: Name : MODULE-STEERING CONTROL C3 Color : # of pins : 4 Pin Description Circuit 1 HORN SWITCH SENSE X3 20DG/VT 2 S/C SWITCH RETURN V937 22DB/DG 2 SENSOR GROUND K900 22DB/DG 3 S/C SWITCH NO. 1 SIGNAL V37 22VT 4 S/C SWITCH NO. 2 SIGNAL V38 22VT/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 685 Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 686 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 687 Connector: Name : MODULE-STEERING CONTROL C4 Color : YELLOW # of pins : 4 Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R61 20LG/VT 2 DRIVER SQUIB 2 LINE 2 R63 20LG/WT 3 DRIVER SQUIB 1 LINE 1 R43 20LG/BR 4 DRIVER SQUIB 1 LINE 2 R45 20LG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 688 Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 689 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 690 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 691 Steering Mounted Controls Communication Module: Diagrams Component ID: 212 Component : MODULE-STEERING CONTROL Connector: Name : MODULE-STEERING CONTROL C1 Color : WHITE # of pins : 6 Pin Description Circuit 1 GROUND Z909 20BK 2 RADIO CONTROL MUX X20 20GY/WT 3 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 4 S/C SWITCH NO. 1 SIGNAL V37 20VT 5 S/C SWITCH RETURN V937 20VT/BR 6 HORN SWITCH SENSE X3 20DG/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 692 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 693 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 694 Connector: Name : MODULE-STEERING CONTROL C2 Color : BLACK # of pins : 2 Qualifier : (PREMIUM) Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 695 2 RADIO CONTROL MUX X20 22GY/WT 2 RADIO CONTROL MUX X20 22GY/WT Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 696 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 697 Connector: Name : MODULE-STEERING CONTROL C3 Color : # of pins : 4 Pin Description Circuit 1 HORN SWITCH SENSE X3 20DG/VT 2 S/C SWITCH RETURN V937 22DB/DG 2 SENSOR GROUND K900 22DB/DG 3 S/C SWITCH NO. 1 SIGNAL V37 22VT 4 S/C SWITCH NO. 2 SIGNAL V38 22VT/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 698 Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 699 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 700 Connector: Name : MODULE-STEERING CONTROL C4 Color : YELLOW # of pins : 4 Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R61 20LG/VT 2 DRIVER SQUIB 2 LINE 2 R63 20LG/WT 3 DRIVER SQUIB 1 LINE 1 R43 20LG/BR 4 DRIVER SQUIB 1 LINE 2 R45 20LG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 701 Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 702 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 703 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set Control Module: Customer Interest Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 714 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 715 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: Customer Interest A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 720 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 721 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set Control Module: Customer Interest A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 726 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 727 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 728 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 729 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set Control Module: All Technical Service Bulletins Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 735 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 736 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: All Technical Service Bulletins A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 741 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 742 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set Control Module: All Technical Service Bulletins A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 747 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 748 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 749 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 750 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 751 Control Module: Locations Component ID: 214 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2-3 POWER TAKEOFF RELAY ENABLE K427 18OR/LG 4-5 PRESSURE SIGNAL 4 T803 20DG/BR 6 PRESSURE SIGNAL 1 T800 20DG/BR 7-8-9-10 - 11 PRESSURE SIGNAL 5 T804 20YL/DB 12 PRESSURE SIGNAL 3 T802 20DG/PK 13 - 14 - 15 - 16 PRESSURE SIGNAL 6 T805 20DG/OR 17 PRESSURE SIGNAL 2 T801 20DG/RD Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 752 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Description Circuit 1 8 VOLT SUPPLY T72 20YL/DB 2 OUTPUT SPEED SIGNAL T14 20DG/BR 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 753 5-6-7 FUSED B(+) A104 20YL/RD 8 GROUND Z133 18BK/LG 9-10 - 11 - 12 - 13 - 14 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 15 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 16 TCC TEMPERATURE SIGNAL T819 20YL/VT 17 GROUND Z133 18BK/LG 18 - 19 SHIFT 4 CONTROL T811 20DG/LB 20 CAN C BUS (+) D65 20WT/LG 21 CAN C BUS (-) D64 20WT/LB 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 754 Pin Description Circuit 1 SHIFT 1 CONTROL T808 20DG/GY 2-3 SHIFT 3 CONTROL T810 20DG/DB 4-5 LINEAR 3 CONTROL T817 20YL/BR 6 LINEAR 1 GROUND T812 20DG/TN 7 LINEAR 1 CONTROL T813 20DG/LG 8 LINEAR 2 CONTROL T815 20YL/RD 9 LINEAR 2 GROUND T814 20YL/BR 10 PRESSURE SIGNAL 7 T806 20DG/VT 11 - 12 - 13 - 14 - - 15 LINEAR 3 GROUND T816 20YL/PK 16 TRS 1 SIGNAL T828 20DG/DB 17 TRS T42 SIGNAL T42 20DG/YL 18 TRS T3 SIGNAL T3 20DG/DB 19 TRS DRIVE SIGNAL T827 20DG/LB 20 TRS PARK SIGNAL T824 20YL/DB 21 TRS REVERSE SIGNAL T826 20DG/DB 22 SHIFT 2 CONTROL T809 20DG/YL 23 - 24 - 25 - 26 PRESSURE SIGNAL 8 T807 20DG/WT 27 - 28 TEMPERATURE SENSOR GROUND T820 20YL/WT 29 TRS NEUTRAL SIGNAL T825 20DG/YL 30 LINEAR 4 CONTROL T821 20YL/GY 31 LINEAR 4 GROUND T818 20YL/OR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 755 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 756 Control Module: Diagrams Component ID: 214 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2-3 POWER TAKEOFF RELAY ENABLE K427 18OR/LG 4-5 PRESSURE SIGNAL 4 T803 20DG/BR 6 PRESSURE SIGNAL 1 T800 20DG/BR 7-8-9-10 - 11 PRESSURE SIGNAL 5 T804 20YL/DB 12 PRESSURE SIGNAL 3 T802 20DG/PK 13 - 14 - 15 - 16 PRESSURE SIGNAL 6 T805 20DG/OR 17 PRESSURE SIGNAL 2 T801 20DG/RD Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 757 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Description Circuit 1 8 VOLT SUPPLY T72 20YL/DB 2 OUTPUT SPEED SIGNAL T14 20DG/BR 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 758 5-6-7 FUSED B(+) A104 20YL/RD 8 GROUND Z133 18BK/LG 9-10 - 11 - 12 - 13 - 14 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 15 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 16 TCC TEMPERATURE SIGNAL T819 20YL/VT 17 GROUND Z133 18BK/LG 18 - 19 SHIFT 4 CONTROL T811 20DG/LB 20 CAN C BUS (+) D65 20WT/LG 21 CAN C BUS (-) D64 20WT/LB 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 759 Pin Description Circuit 1 SHIFT 1 CONTROL T808 20DG/GY 2-3 SHIFT 3 CONTROL T810 20DG/DB 4-5 LINEAR 3 CONTROL T817 20YL/BR 6 LINEAR 1 GROUND T812 20DG/TN 7 LINEAR 1 CONTROL T813 20DG/LG 8 LINEAR 2 CONTROL T815 20YL/RD 9 LINEAR 2 GROUND T814 20YL/BR 10 PRESSURE SIGNAL 7 T806 20DG/VT 11 - 12 - 13 - 14 - - 15 LINEAR 3 GROUND T816 20YL/PK 16 TRS 1 SIGNAL T828 20DG/DB 17 TRS T42 SIGNAL T42 20DG/YL 18 TRS T3 SIGNAL T3 20DG/DB 19 TRS DRIVE SIGNAL T827 20DG/LB 20 TRS PARK SIGNAL T824 20YL/DB 21 TRS REVERSE SIGNAL T826 20DG/DB 22 SHIFT 2 CONTROL T809 20DG/YL 23 - 24 - 25 - 26 PRESSURE SIGNAL 8 T807 20DG/WT 27 - 28 TEMPERATURE SENSOR GROUND T820 20YL/WT 29 TRS NEUTRAL SIGNAL T825 20DG/YL 30 LINEAR 4 CONTROL T821 20YL/GY 31 LINEAR 4 GROUND T818 20YL/OR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 760 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description Control Module: Description and Operation Description DESCRIPTION On gasoline vehicles the Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). 68RFE TCM LOCATION Vehicles equipped 68RFE transmission and a 6.7L Diesel engine, the TCM is housed in the NGC4 controller utilizing only the C1 and C4 connectors (TCM only). The controller is located at the rear of the engine compartment, near the right inner fender. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 763 AS68RC TCM LOCATION On Cab Chassis models equipped with the AS68RC transmission the Transmission Control Module (TCM) has three electrical connectors and is located in the passenger compartment underneath of the left side of the dash panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 764 Control Module: Description and Operation Operation OPERATION RLE and RFE TRANSMISSIONS The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) (if equipped) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 765 An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 766 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 767 SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 768 AISIN AS68RC TRANSMISSION The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Speed Sensor - Output Speed Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 769 - Manifold Pressure - Throttle position - Torque Reduction Confirmation - Engine Coolant Temperature - Exhaust Brake Status (if equipped) - PTO Request (if equipped) - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Exhaust Brake Cut Request (if equipped). - Solenoids. - Torque Reduction Request. Some examples of TCM .indirect outputs are: - Transmission Temperature (to PCM). - PRNDL Position (to cluster/CCN). - PTO Status. In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI). - Storing and selecting appropriate Shift Schedules. - System self-diagnostics. - Diagnostic capabilities (with scan tool). Clutch filling time is continuously maintained when the vehicle is running. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 774 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 775 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 776 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 777 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 778 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 779 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 780 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 781 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 782 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 783 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 784 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 785 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 786 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 787 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 788 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 789 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 790 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 791 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 792 Transmission Control System Relay: Connector Views Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > AS68RC Automatic Transmission Transmission Control System Relay: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION AS68RC Automatic Transmission NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. The relay is supplied fused B+ voltage, energized by the TIPM, and is used to supply power to the TCM when the transmission is in normal operating mode. Operation OPERATION The TIPM energizes the transmission control relay. When the relay is "off", no power is supplied to the TCM and the transmission will not operate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Control Module: Locations Component ID: 204 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 LOCKER SENSOR SUPPLY T521 20YL/BK A2 LOCKER SWITCH SUPPLY T537 20YL/LG A3 LOCKER SENSOR SUPPLY T523 20YL/BK A4 - A5 - A6 CAN C BUS (+) D65 20WT/LG A7 CAN C BUS (-) D64 20WT/LB A8 REAR LOCKER SENSOR SENSE T527 20YL/TN A9 FRONT LOCKER SENSOR SENSE T522 20YL/LB A10 LOCKER SWITCH SENSE T535 20YL/BR A11 - A12 - A13 - A14 - B FUSED B(+) A121 14RD/YL B1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG B2 SWITCH SUPPLY T536 20YL/WT B3 - B4 - B5 STABILIZER BAR SWITCH SENSE T531 20YL/TN B6 LOCKER OPEN ILLUMINATION SENSE T532 20YL/GY B7 LOCKER REAR ILLUMINATION SENSE T533 20YL/LB B8 LOCKER FR/RR ILLUMINATION SENSE T534 20YL B9 STABILIZER BAR DISENGAGE ILLUMINATION SENSE T530 20YL/DG B10 STABILIZER BAR ENGAGE ILLUMINATION SENSE T529 20YL/LG B11 - B12 - B13 - B14 - C FRONT LOCKER SOURCE T520 16YL/OR C1 - C2 - C3 - C4 - C5 - - Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 799 C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - D REAR LOCKER SOURCE T526 16YL/WT E GROUND Z935 16BK F GROUND Z935 16BK G FRONT LOCKER RETURN T524 16YL/LG H REAR LOCKER RETURN T528 16YL/GY Component Location - 29 Component Location - 28 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 800 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 801 Control Module: Diagrams Component ID: 204 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 LOCKER SENSOR SUPPLY T521 20YL/BK A2 LOCKER SWITCH SUPPLY T537 20YL/LG A3 LOCKER SENSOR SUPPLY T523 20YL/BK A4 - A5 - A6 CAN C BUS (+) D65 20WT/LG A7 CAN C BUS (-) D64 20WT/LB A8 REAR LOCKER SENSOR SENSE T527 20YL/TN A9 FRONT LOCKER SENSOR SENSE T522 20YL/LB A10 LOCKER SWITCH SENSE T535 20YL/BR A11 - A12 - A13 - A14 - B FUSED B(+) A121 14RD/YL B1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG B2 SWITCH SUPPLY T536 20YL/WT B3 - B4 - B5 STABILIZER BAR SWITCH SENSE T531 20YL/TN B6 LOCKER OPEN ILLUMINATION SENSE T532 20YL/GY B7 LOCKER REAR ILLUMINATION SENSE T533 20YL/LB B8 LOCKER FR/RR ILLUMINATION SENSE T534 20YL B9 STABILIZER BAR DISENGAGE ILLUMINATION SENSE T530 20YL/DG B10 STABILIZER BAR ENGAGE ILLUMINATION SENSE T529 20YL/LG B11 - B12 - B13 - B14 - C FRONT LOCKER SOURCE T520 16YL/OR C1 - C2 - C3 - C4 - C5 - - Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 802 C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - D REAR LOCKER SOURCE T526 16YL/WT E GROUND Z935 16BK F GROUND Z935 16BK G FRONT LOCKER RETURN T524 16YL/LG H REAR LOCKER RETURN T528 16YL/GY Component Location - 29 Component Location - 28 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 803 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description Control Module: Description and Operation Description DESCRIPTION The Transfer Case Control Module (TCCM) functionality now resides in the Totally Integrated Power Module (TIPM), refer to the TIPM information for location. The TIPM controls the 4X4 transfer case shift functions via the actuation of a shift motor and utilizing the feedback of a mode sensor assembly. Communication is via the CAN bus. Inputs include user selectable 4X4 modes that include 2WD, AWD, 4HI, 4LO, and Neutral (selections vary with the specific transfer case). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 806 Control Module: Description and Operation Operation OPERATION The Transfer Case Control Module (TCCM) functionality in the Totally Integrated Power Module (TIPM) utilizes the input from the transfer case mounted mode sensor, the instrument panel mounted selector switch, and the following information from the vehicle's CAN bus to determine if a shift is allowed. - Engine RPM and Vehicle Speed - Diagnostic Requests - Manual Transmission and Brake Applied - PRNDL - Ignition Status - ABS Messages Once the TIP determines that a requested shift is allowed, it actuates the bi-directional shift motor as necessary to achieve the desired transfer case operating mode. The TIPM also monitors the mode sensor while controlling the shift motor to determine the status of the shift attempt. Several items can cause the requested shift not to be completed. If the TIPM has recognized a fault (DTC) of some variety, it will begin operation in one of four Functionality Levels. These levels are: - Level Zero - Normal Operation. - Level One - Only Mode Shifts Are Allowed. - Level Two - Only Mode Shifts and Shifts Into LOW Are Allowed (No Neutral Shifts Are Allowed). - Level Three - No Shifts Are Allowed The TIPM can also be operating in one of three possible power modes. These power modes are: - Full Power Mode is the normal operational mode of the module. This mode is achieved by normal CAN bus traffic being present and the ignition being in the RUN position. Reduced Power Mode will be entered when the ignition has been powered off. In this state, the module will shut down power supplied to external devices, and to electronic interface inputs and outputs. From this state the module can enter either Sleep Mode or Full Power Mode. To enter this mode, the module must receive an ignition message denoting that the ignition is off, or not receive any messages for 5 ± 0.5 seconds. To exit this mode, the module must receive one ignition message that denotes that the ignition is in the RUN position. - Sleep Mode will be entered, from the Reduced Power Mode, when no CAN traffic has been sensed for 20 ± 1 seconds. If during Sleep Mode the module detects CAN bus traffic, it will revert to the Reduced Power mode while monitoring for ignition messages. It will remain in this state as long as there is traffic other than run or start messages, and will return to Sleep mode if the bus goes without traffic for 20 ± 1 seconds. SHIFT REQUIREMENTS If the TIPM is in full power mode and at functionality level zero, it uses the following criteria to determine if a shift is allowed. If any of the driver controllable conditions are not met once the shift request is recognized, the TIPM will solidly illuminate the source position's LED and flash the desired position's LED for all shifts except NEUTRAL. The NEUTRAL shift LED strategy will be discussed later. Mode shifts will be allowed regardless of transmission gear or vehicle speed, whenever the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - A change in the Selector switch state indicates that a mode shift has been requested. - A valid mode sensor signal is being sensed by the TIPM. - Proper transmit/receive messages are occurring on the CAN bus. - Ignition key switch is in the RUN position. Range shifts will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - A change in the Selector Switch state indicating a range shift has been requested. - Transmission in NEUTRAL signal must be recognized for at least 1.5 seconds ± 100 msec. (Automatic transmissions only) - Proper transmit/receive messages are occurring on the CAN bus. - Clutch signal is recognized for 500 msec ± 50 msec (Manual transmissions only). - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position. - A valid mode sensor signal is being sensed by the TIPM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 807 A shift into transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 4.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus. (Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the CAN bus. - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position, engine off. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TIPM. A shift out of transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 1.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus.(Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the CAN bus. - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TIPM. SHIFT SEQUENCES Once all the driver controllable conditions for the requested shift have been met, the TIPM begins a shift timer with a maximum duration of 1 second per 'D' channel transition. If the shift timer expires before the TIPM recognizes to correct mode sensor code, the shift is considered to have been blocked. The blocked shift will increment the blocked shift counter by one. The TIPM strategy for handling blocked shifts will be described later. The process the TIPM performs for the various shifts will be described first. RANGE AND MODE SHIFTS The process for performing all the range and mode shifts are the same. The following steps describe the process. - Allow time for Selector Switch debounce; 250 msec ± 50 msec. - Extinguish the source gear's LED while flashing desired transfer case position's LED. - Engage the shift motor for a maximum of 1 second ± 100 msec per 'D' channel transition in the destination gear's direction while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Solidly illuminate the selected gear's LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds ± 100 msec. per 'D' channel. The TIPM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. The exception to the preceding sequence is when a shift from 4L to 2WD/AWD is requested. If 2WD/AWD is requested from the 4L position, the transfer case is first driven to the 4H position. If the 4H position is reached, the transfer case is then driven back to the 2WD/AWD position and the shift is considered complete. If the transfer case does not reach any the 4H position, but is in the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is also considered complete. SHIFT OUT OF NEUTRAL The following steps describe the process for a shift out of NEUTRAL. - Extinguish the Neutral LED. - Engage the shift motor for a maximum of 1 second ± 100 msec toward the transfer case 4H mode position while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Extinguish the Neutral LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds 100 msec. The Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 808 TIPM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. - When the Neutral button is released, if the 4H position is the desired position, the shift is complete. Illuminate the 4H LED. - Otherwise when the Neutral button is released, if all of the shift requirements are being met then engage the shift motor towards the desired position for 1 second ± 100 msec per 'D' channel. (if requirements for shifting are not met, illuminate the 4H LED and flash the destination LED as an indication to the driver that all of the driver controllable shift conditions are not being met). If this requires another range or mode shift, begin the range/mode shift process. - If the desired mode sensor code is not received after the shift timer expires (i.e. a blocked or other condition exists), refer to Blocked Shift Strategy. BLOCKED SHIFT STRATEGY When a shift is commanded, the shift motor will be driven towards its destination position, except in the case of shifting out of Neutral if 4L was selected (the transfer case will shift to the 4H position first, before proceeding to 4L). If the shift is blocked on the way to the destination, the TIPM may attempt to drive the motor back to the original position. This process will be allowed to occur 5 times. If the transfer case has reached a non-NEUTRAL 'D' channel during the shift re-attempts, the LED for the achieved gear position is illuminated and the shift attempts are stopped. To re-attempt the desired shift, the selector switch will need to be rotated to the current position until the switch debounce timer expires then a shift will need to be requested again. At the end of the 5th blocked attempt, the shift motor is driven towards the last known 'D' channel position. If this motor drive allows the transfer case to reach the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is considered complete and the shift attempts are ended. If the mode sensor is in the NEUTRAL region at the expiration of the shift timer, the TIPM will continue to make the shift attempts according to the blocked shift strategy independent of whether or not the driver controlled conditions are met. For shifts from NEUTRAL, if all 5 attempts fail to reach the desired position (which by default is 4H), the motor will be driven to stall in the direction of 4H or 4L, depending on the achieved position. If the transfer case has reached the 2WD/AWD or 4L between gear position nearest the NEUTRAL positions and the shift conditions are no longer being met, the transfer case will be driven toward the corresponding 'D' channel. Otherwise, the transfer case will be driven in the direction opposite the last attempt with the desired target being 4H or 4L. If the transfer case reaches the 2WD/AWD 'D' channel when being driven in the 4H direction, then one final 1.0 second drive toward 4H is attempted. If the transfer case then reaches any of the 4H positions, the shift is considered complete and the 4H LED is illuminated. If the transfer case is still the 2WD/AWD position, the shift is considered complete and the 2WD/AWD LED is illuminated. NOTE: If after the 5th blocked shift and reversal attempt, if the transfer case position is in the NEUTRAL region, shift attempts will continue until a non-NEUTRAL 'D' channel is reached. SHIFT REVERSAL TARGETS If the shift timer expires (1 second per 'D' channel) and the transfer case has not reached the desired position, all shifts will attempt to return to their original position with the exceptions of: - If the intended shift is going to the High rail from Low and can't make it, but it can make the 2WD/AWD position, the motor stops at that position. The TIPM will not attempt to cross back over NEUTRAL if it does not have to. This means that there was a block on the first attempt to go to 4H and the transfer case has made it through NEUTRAL to a known good position, then the motor will go back only to the 2WD/4WD position and execute the remainder of the attempts from there. - For shifts out of NEUTRAL, any time a shift is commanded out of NEUTRAL, the system needs to get out. The TIPM should never go to NEUTRAL unless the driver is commanding it and all required conditions are being met ENCODER DRIFT CORRECTION Whenever a shift is completed, the TIPM stores the position in memory as the transfer case's intended position. The TIPM continuously monitors the mode sensor and if the mode sensor drifts toward into a NEUTRAL region sensor position for 2.0 seconds, the TIPM will perform a motor drive to correct the drift. The transfer case will be driven toward the intended position for 1.0 seconds ± 100 msec. The TIPM will wait for 2.0 seconds ± 50 msec. and repeat the attempt to shift to the desired position. This will continue until the intended position is reached. SHIFT MOTOR BRAKING Two modes of shift motor braking are employed to improve shift performance, static and dynamic. Static shift motor braking is utilized under the following conditions: - Whenever the transfer case is in the 2WD/AWD or 4L 'D' channel position. - Whenever an invalid mode sensor code is present. Static motor braking is achieved by applying +12V on both shift motor wires. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 809 NOTE: Static Shift Motor Braking is independent of ignition key position. SHIFT ATTEMPT LIMIT To protect the transfer case system, the TIPM will impose a limit on the number of shifts that can occur over a calibrated time period. The system will monitor the number of 'D' channel segment transitions that occur in any 30 second time period. If the number of segment transitions is 30 or greater, the system will go into a default mode. The default mode of operation for shifting is that the number of allowed 'D' channel transitions permitted to occur will be 3 over each 15 second ± 100 msec calibrated window of time. After 5 minutes ± 100 msec, the motor can be assumed to have cooled down and the system will revert to normal operation. The following rules also apply to the shift limit: - The attempt limit will not prevent shifts coming out of NEUTRAL, they will be allowed regardless of the counter/timer. - Any shift that is in progress when the counter reaches a maximum count in time will be allowed to complete before the default mode is entered. D-channel transitions during this period will not be counted towards the default mode limit. - A block, regardless of the direction, whether towards destination or back towards reversal target (shift timer expiring), will count as a value of 2 transitions towards the 30 segment transitions to go into default mode as defined above. Current attempt limit values are 30 transitions in 30 seconds and default mode values are 3 transitions every 15 seconds for 5 minutes. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 814 Heated Glass Element Relay: Description and Operation Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations Rear Defogger Relay: Locations Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations > Page 818 Rear Defogger Relay: Description and Operation Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Dodge Ram 2006-2008, 1500-5500 all, do not use a wiper relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 823 Wiper Relay: Description and Operation Dodge Ram 2006-2009, does not use a wiper relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Customer Interest for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood Hood Sensor/Switch (For Alarm): Customer Interest Antitheft System - Goes Off When Opening The Hood NUMBER: 08-040-06 GROUP: Electrical DATE: September 06, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: Vehicle Theft Security System Alarm May Alert When Hood Is Opened OVERVIEW: This bulletin involves selectively erasing and reprogramming the Cabin Compartment Node Module (CCN) with new software. MODELS: 2007 (DR/DH/D1/DC) Ram Truck NOTE: This bulletin applies to vehicles equipped with a remote start system (sales code XBM) prior to October 10, 2006 (MDH 1010XX). SYMPTOM/CONDITION: The Vehicle Theft Security System (VTSS) may alert (flash lights and/or sound horn) if one of the following occurs: a. The customer arms the VTSS and then reaches through an open window, pulls on the hood release, and fully opens the vehicle hood. b. The customer releases the hood but not enough to open the hood ajar switch, arms the VTSS, and then fully opens the vehicle hood. c. The customer opens the hood, arms the VTSS, the vehicle communications bus goes in to "sleep mode" (may take 10 minutes), then the "LOCK" button on the key fob is depressed. The hood ajar switch is not part of the VTSS used on domestic use vehicles. The hood ajar switch is used for export vehicles equipped with the Vehicle Theft Alarm (VTA) system. DIAGNOSIS: 1. Connect the StarSCAN(R) to the vehicle. 2. Power up the StarSCAN(R) and obtain the HOME menu. 3. From the HOME menu select "ECU VIEW". 4. Select "CCN - Cabin Compartment". 5. Select "More Options". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Customer Interest for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 834 6. Select "ECU Flash" 7. Read and record the software part number that is display with "Resident Flash File For Part". 8. Is the software part number 05172187AC (or later)? a. If YES >>> then STOP. This bulletin does not apply. Further diagnosis is required. b. If NO >>> then perform the Repair Procedure. NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the CCN in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash CCN" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Customer Interest for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 835 13. Highlight the listed calibration. 14. Select "Update Controller". Follow on screen instructions. 15. When the CCN update is complete, select "OK". 16. Verify the part number at the top of the "Flash CCN" screen has updated to the new part number. NOTE: Due to the CCN programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood Hood Sensor/Switch (For Alarm): All Technical Service Bulletins Antitheft System - Goes Off When Opening The Hood NUMBER: 08-040-06 GROUP: Electrical DATE: September 06, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: Vehicle Theft Security System Alarm May Alert When Hood Is Opened OVERVIEW: This bulletin involves selectively erasing and reprogramming the Cabin Compartment Node Module (CCN) with new software. MODELS: 2007 (DR/DH/D1/DC) Ram Truck NOTE: This bulletin applies to vehicles equipped with a remote start system (sales code XBM) prior to October 10, 2006 (MDH 1010XX). SYMPTOM/CONDITION: The Vehicle Theft Security System (VTSS) may alert (flash lights and/or sound horn) if one of the following occurs: a. The customer arms the VTSS and then reaches through an open window, pulls on the hood release, and fully opens the vehicle hood. b. The customer releases the hood but not enough to open the hood ajar switch, arms the VTSS, and then fully opens the vehicle hood. c. The customer opens the hood, arms the VTSS, the vehicle communications bus goes in to "sleep mode" (may take 10 minutes), then the "LOCK" button on the key fob is depressed. The hood ajar switch is not part of the VTSS used on domestic use vehicles. The hood ajar switch is used for export vehicles equipped with the Vehicle Theft Alarm (VTA) system. DIAGNOSIS: 1. Connect the StarSCAN(R) to the vehicle. 2. Power up the StarSCAN(R) and obtain the HOME menu. 3. From the HOME menu select "ECU VIEW". 4. Select "CCN - Cabin Compartment". 5. Select "More Options". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 841 6. Select "ECU Flash" 7. Read and record the software part number that is display with "Resident Flash File For Part". 8. Is the software part number 05172187AC (or later)? a. If YES >>> then STOP. This bulletin does not apply. Further diagnosis is required. b. If NO >>> then perform the Repair Procedure. NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the CCN in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash CCN" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 842 13. Highlight the listed calibration. 14. Select "Update Controller". Follow on screen instructions. 15. When the CCN update is complete, select "OK". 16. Verify the part number at the top of the "Flash CCN" screen has updated to the new part number. NOTE: Due to the CCN programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 843 Hood Sensor/Switch (For Alarm): Locations Component ID: 469 Component : SWITCH-HOOD AJAR Connector: Name : SWITCH-HOOD AJAR Color : # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 HOOD AJAR SWITCH SENSE G70 20VT/LB 2 AAT RETURN G930 20VT/TN Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 844 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 845 Hood Sensor/Switch (For Alarm): Diagrams Component ID: 469 Component : SWITCH-HOOD AJAR Connector: Name : SWITCH-HOOD AJAR Color : # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 HOOD AJAR SWITCH SENSE G70 20VT/LB 2 AAT RETURN G930 20VT/TN Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 846 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Description Hood Sensor/Switch (For Alarm): Description and Operation Description DESCRIPTION The hood ajar switch is a normally closed, single pole, spring-loaded plunger actuated switch. This switch has two unique versions that are used in two different applications. One switch is used only on vehicles equipped with the Vehicle Theft Alarm (VTA) system for sale in certain export markets where protection of the underhood area is required equipment. The second switch is used only on domestic vehicles equipped with an optional remote starter system. The molded plastic switch body (5) has an integral molded connector receptacle (1) on the lower end containing two terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the headlamp and dash wire harness. Two integral latches (2) lock the switch into a keyed mounting hole in the stamped steel switch mounting bracket. The mounting bracket is secured with screws to the inboard side of the right front fender load beam within the engine compartment. A molded plastic striker secured to the underside of the hood panel inner reinforcement actuates the switch plunger as the hood panel is closed. The switch plunger (3) extends through a mounting collar (4) and a sleeve-like retainer ring on the upper end of the switch body. The retainer ring has a one time, self-adjustment feature that is activated after the switch is installed by closing the hood. The retainer ring is also color-coded to aid in identifying the switch application. A dark brown retainer ring identifies the underhood security switch application, while a white retainer ring identifies the remote starter system application. An installed hood ajar switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or requires readjustment, it must be replaced with a new unit. The hood ajar switch striker is not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced with a new unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Description > Page 849 Hood Sensor/Switch (For Alarm): Description and Operation Operation OPERATION The hood ajar switches are interchangeable physically, but not functionally. In each case, the hood ajar switch is a normally closed switch that is held open as the spring-loaded switch plunger is depressed by the striker on the inner hood panel reinforcement when the hood panel is closed and latched. When the hood is opened, the spring-loaded switch plunger extends from the switch body and the switch contacts are closed. In the underhood security application (export vehicles only - dark brown retainer ring), the switch is connected in series between ground and the hood ajar switch sense input of the Totally Integrated Power Module (TIPM). The TIPM uses an internal resistor pull up to monitor the state of the hood ajar switch contacts. In the remote starter system application (domestic vehicles only - white retainer ring) the switch has a 1 kilo ohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between an output of the TIPM and the hood ajar switch sense input of the TIPM. The TIPM continually monitors this circuit and will store a Diagnostic Trouble Code (DTC) for any fault that it detects. The components of the switch self-adjustment feature include an integral stop on the shaft of the plunger and a ribbed, ratcheting sleeve-like retainer ring at the top of the switch body from which the plunger extends. With the switch mounting collar secured in its mounting bracket, the plunger is depressed by the striker on the hood inner reinforcement as the hood is closed. As the plunger is depressed, the plunger stop contacts the top of the retainer ring and it is driven downward, ratcheting through the switch mounting collar until the hood is fully closed and latched. The ribs on the retainer ring are engaged within the mounting collar to maintain this adjusted position. The hood ajar switch as well as the hard wired circuits between the switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between modules and other devices related to hood ajar switch operation that provide some features of the export vehicle theft or domestic remote starter systems. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to hood ajar switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal Hood Sensor/Switch (For Alarm): Service and Repair Removal Striker STRIKER NOTE: The hood ajar switch striker is not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Unlatch and open the hood. 2. Using a trim stick or another suitable wide flat-bladed tool, pry the rearward end of the hood ajar switch striker (2) away from the inner hood panel reinforcement (1) far enough to disengage the integral retainers from their mounting holes. 3. Remove the striker from the inner hood panel reinforcement and discard. Bracket BRACKET 1. Remove the hood ajar switch (2) from the mounting bracket (3). 2. Remove the two screws (4) that secure the hood ajar switch bracket to the two rivet nuts (1) in the right front load beam (6). 3. Remove the hood ajar switch mounting bracket from the inboard side of the right front load beam. Switch SWITCH Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal > Page 852 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. From the top of the mounting bracket (3) on the right front load beam (6), squeeze the two hood ajar switch (2) latch tabs together and pull the switch upward. 4. Pull the hood ajar switch up through the hole in the mounting bracket far enough to access and disconnect the jumper wire harness connector (5) from the switch connector receptacle. 5. Remove the hood ajar switch from the mounting bracket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal > Page 853 Hood Sensor/Switch (For Alarm): Service and Repair Installation Striker STRIKER NOTE: The hood ajar switch striker cap is not intended for reuse. If the striker cap is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Position the new hood ajar switch striker (2) to the mounting holes in the inner hood panel reinforcement (1) over the hood ajar switch (3). 2. Using hand pressure, press the hood ajar switch striker upward into the mounting holes in the inner hood panel reinforcement until both integral retainers are fully engaged. 3. Close and latch the hood. Bracket BRACKET 1. Check to be certain that the two rivet nuts (1) on the inboard side of the right front load beam (6) are in good condition and properly secured. 2. Position the hood ajar switch mounting bracket (3) onto the right front load beam. 3. Install and tighten the two screws (4) that secure the mounting bracket to the load beam. Beginning with the rearward screw, tighten both screws to 8 Nm (71 in. lbs.). 4. Reinstall the hood ajar switch (2) into the mounting bracket. Switch Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal > Page 854 SWITCH 1. Position the hood ajar switch (2) near the hole in the mounting bracket (3) on the right front load beam (6). 2. Route the jumper wire harness connector (5) through the switch mounting bracket and reconnect it to the switch connector receptacle. 3. From the top of the mounting bracket, press the switch downward into the mounting hole until the integral switch latch tabs lock it into place. 4. Reconnect the battery negative cable. 5. Close and latch the hood. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Component ID: 457 Component : SWITCH-ADJUSTABLE PEDALS Connector: Name : SWITCH-ADJUSTABLE PEDALS Color : BLUE # of pins : 6 Qualifier : (EXCEPT BASE) Pin Description Circuit 1 ADJUSTABLE PEDALS MOTOR REARWARDP206 18LG/LB 2 ADJUSTABLE PEDALS OUTPUT A72 18RD/OR 3-4 GROUND Z146 18BK 5 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 6 ADJUSTABLE PEDALS MOTOR FORWARD P205 18LG/WT Component Location - 44 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 858 Component Location - 50 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 859 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 860 Pedal Positioning Switch: Diagrams Component ID: 457 Component : SWITCH-ADJUSTABLE PEDALS Connector: Name : SWITCH-ADJUSTABLE PEDALS Color : BLUE # of pins : 6 Qualifier : (EXCEPT BASE) Pin Description Circuit 1 ADJUSTABLE PEDALS MOTOR REARWARDP206 18LG/LB 2 ADJUSTABLE PEDALS OUTPUT A72 18RD/OR 3-4 GROUND Z146 18BK 5 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 6 ADJUSTABLE PEDALS MOTOR FORWARD P205 18LG/WT Component Location - 44 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 861 Component Location - 50 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 862 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Service and Repair > Removal Pedal Positioning Switch: Service and Repair Removal REMOVAL 1. Remove the lower drivers side bezel (4). 2. Disconnect the electrical connector (3) from the adjustable pedal switch (2). 3. Remove the switch (2) from the lower drivers side bezel (4) by squeezing the retaining clips together and pushing the switch outwards. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Service and Repair > Removal > Page 865 Pedal Positioning Switch: Service and Repair Installation INSTALLATION 1. Install the switch (2) to the lower drivers side bezel (4) by pushing the switch inwards seating the retaining clips to the lower drivers side bezel (4). 2. Reconnect the electrical connector (3) to the adjustable pedal switch (2). 3. Install the lower drivers side bezel (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Description Remote Switch: Description and Operation Description DESCRIPTION Two rocker-type switches (if equipped) are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player, CD player or CD changer (if equipped). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Description > Page 870 Remote Switch: Description and Operation Operation OPERATION The six switches in the two remote radio switch units are normally open, resistor multiplexed momentary switches that are hard wired to the Totally Integrated Power Module (TIPM) through the clockspring. The TIPM sends a five volt reference signal to both switch units on one circuit, and senses the status of all of the switches by reading the voltage drop on a second circuit. When the TIPM senses an input (voltage drop) from any one of the remote radio switches, it sends the proper switch status messages on the Programmable Communication Interface (PCI) data bus network to the radio receiver. The electronic circuitry within the radio receiver is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. For diagnosis of the TIPM or the PCI data bus, the use of a scan tool and the proper Diagnostic Procedures information is recommended. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 871 Remote Switch: Testing and Inspection REMOTE SWITCHES Any diagnosis of the Audio system should begin with the use of scan tool. For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the remote radio switch(es) from the steering wheel. 3. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test chart. If the remote radio switch resistances check OK, go to STEP 4. If not OK, replace the faulty switch. 4. Connect the battery negative cable. Turn the ignition switch to the On position. Check for 5 volts at the radio control mux circuit cavities of the steering wheel wire harness connectors for both remote radio switches. If OK, go to STEP 5. If not OK, repair the open or shorted radio control mux circuit to the Totally Integrated Power Module (TIPM) as required. 5. Disconnect and isolate the battery negative cable. Disconnect the 22-way instrument panel wire harness connector from the TIPM. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and a good ground. There should be no continuity. If OK, go to STEP 6. If not OK, repair the shorted remote radio switch ground circuit to the TIPM as required. 6. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and the 22-way instrument panel wire harness connector for the TIPM. There should be continuity. If OK, refer to the proper Diagnostic Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 872 Procedures to test the TIPM and the PCI data bus. If not OK, repair the open remote radio switch ground circuit as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Removal Remote Switch: Service and Repair Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag. 3. Remove the speed control switches (2). 4. Unplug the wire harness connector from the remote radio switch (1). 5. Depress the tabs on each side of each switch and push the switch through the rear steering wheel cover. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Removal > Page 875 Remote Switch: Service and Repair Installation INSTALLATION WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Install remote radio switch (1) to the steering wheel. 2. Connect the wire harness to the remote radio switch. 3. Install the speed control switches (2). 4. Install the driver airbag. 5. Connect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Customer Interest for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood Hood Sensor/Switch (For Alarm): Customer Interest Antitheft System - Goes Off When Opening The Hood NUMBER: 08-040-06 GROUP: Electrical DATE: September 06, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: Vehicle Theft Security System Alarm May Alert When Hood Is Opened OVERVIEW: This bulletin involves selectively erasing and reprogramming the Cabin Compartment Node Module (CCN) with new software. MODELS: 2007 (DR/DH/D1/DC) Ram Truck NOTE: This bulletin applies to vehicles equipped with a remote start system (sales code XBM) prior to October 10, 2006 (MDH 1010XX). SYMPTOM/CONDITION: The Vehicle Theft Security System (VTSS) may alert (flash lights and/or sound horn) if one of the following occurs: a. The customer arms the VTSS and then reaches through an open window, pulls on the hood release, and fully opens the vehicle hood. b. The customer releases the hood but not enough to open the hood ajar switch, arms the VTSS, and then fully opens the vehicle hood. c. The customer opens the hood, arms the VTSS, the vehicle communications bus goes in to "sleep mode" (may take 10 minutes), then the "LOCK" button on the key fob is depressed. The hood ajar switch is not part of the VTSS used on domestic use vehicles. The hood ajar switch is used for export vehicles equipped with the Vehicle Theft Alarm (VTA) system. DIAGNOSIS: 1. Connect the StarSCAN(R) to the vehicle. 2. Power up the StarSCAN(R) and obtain the HOME menu. 3. From the HOME menu select "ECU VIEW". 4. Select "CCN - Cabin Compartment". 5. Select "More Options". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Customer Interest for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 886 6. Select "ECU Flash" 7. Read and record the software part number that is display with "Resident Flash File For Part". 8. Is the software part number 05172187AC (or later)? a. If YES >>> then STOP. This bulletin does not apply. Further diagnosis is required. b. If NO >>> then perform the Repair Procedure. NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the CCN in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash CCN" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Customer Interest for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 887 13. Highlight the listed calibration. 14. Select "Update Controller". Follow on screen instructions. 15. When the CCN update is complete, select "OK". 16. Verify the part number at the top of the "Flash CCN" screen has updated to the new part number. NOTE: Due to the CCN programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood Hood Sensor/Switch (For Alarm): All Technical Service Bulletins Antitheft System - Goes Off When Opening The Hood NUMBER: 08-040-06 GROUP: Electrical DATE: September 06, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: Vehicle Theft Security System Alarm May Alert When Hood Is Opened OVERVIEW: This bulletin involves selectively erasing and reprogramming the Cabin Compartment Node Module (CCN) with new software. MODELS: 2007 (DR/DH/D1/DC) Ram Truck NOTE: This bulletin applies to vehicles equipped with a remote start system (sales code XBM) prior to October 10, 2006 (MDH 1010XX). SYMPTOM/CONDITION: The Vehicle Theft Security System (VTSS) may alert (flash lights and/or sound horn) if one of the following occurs: a. The customer arms the VTSS and then reaches through an open window, pulls on the hood release, and fully opens the vehicle hood. b. The customer releases the hood but not enough to open the hood ajar switch, arms the VTSS, and then fully opens the vehicle hood. c. The customer opens the hood, arms the VTSS, the vehicle communications bus goes in to "sleep mode" (may take 10 minutes), then the "LOCK" button on the key fob is depressed. The hood ajar switch is not part of the VTSS used on domestic use vehicles. The hood ajar switch is used for export vehicles equipped with the Vehicle Theft Alarm (VTA) system. DIAGNOSIS: 1. Connect the StarSCAN(R) to the vehicle. 2. Power up the StarSCAN(R) and obtain the HOME menu. 3. From the HOME menu select "ECU VIEW". 4. Select "CCN - Cabin Compartment". 5. Select "More Options". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 893 6. Select "ECU Flash" 7. Read and record the software part number that is display with "Resident Flash File For Part". 8. Is the software part number 05172187AC (or later)? a. If YES >>> then STOP. This bulletin does not apply. Further diagnosis is required. b. If NO >>> then perform the Repair Procedure. NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the CCN in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash CCN" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 894 13. Highlight the listed calibration. 14. Select "Update Controller". Follow on screen instructions. 15. When the CCN update is complete, select "OK". 16. Verify the part number at the top of the "Flash CCN" screen has updated to the new part number. NOTE: Due to the CCN programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 895 Hood Sensor/Switch (For Alarm): Locations Component ID: 469 Component : SWITCH-HOOD AJAR Connector: Name : SWITCH-HOOD AJAR Color : # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 HOOD AJAR SWITCH SENSE G70 20VT/LB 2 AAT RETURN G930 20VT/TN Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 896 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 897 Hood Sensor/Switch (For Alarm): Diagrams Component ID: 469 Component : SWITCH-HOOD AJAR Connector: Name : SWITCH-HOOD AJAR Color : # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 HOOD AJAR SWITCH SENSE G70 20VT/LB 2 AAT RETURN G930 20VT/TN Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 898 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Description Hood Sensor/Switch (For Alarm): Description and Operation Description DESCRIPTION The hood ajar switch is a normally closed, single pole, spring-loaded plunger actuated switch. This switch has two unique versions that are used in two different applications. One switch is used only on vehicles equipped with the Vehicle Theft Alarm (VTA) system for sale in certain export markets where protection of the underhood area is required equipment. The second switch is used only on domestic vehicles equipped with an optional remote starter system. The molded plastic switch body (5) has an integral molded connector receptacle (1) on the lower end containing two terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the headlamp and dash wire harness. Two integral latches (2) lock the switch into a keyed mounting hole in the stamped steel switch mounting bracket. The mounting bracket is secured with screws to the inboard side of the right front fender load beam within the engine compartment. A molded plastic striker secured to the underside of the hood panel inner reinforcement actuates the switch plunger as the hood panel is closed. The switch plunger (3) extends through a mounting collar (4) and a sleeve-like retainer ring on the upper end of the switch body. The retainer ring has a one time, self-adjustment feature that is activated after the switch is installed by closing the hood. The retainer ring is also color-coded to aid in identifying the switch application. A dark brown retainer ring identifies the underhood security switch application, while a white retainer ring identifies the remote starter system application. An installed hood ajar switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or requires readjustment, it must be replaced with a new unit. The hood ajar switch striker is not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced with a new unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Description > Page 901 Hood Sensor/Switch (For Alarm): Description and Operation Operation OPERATION The hood ajar switches are interchangeable physically, but not functionally. In each case, the hood ajar switch is a normally closed switch that is held open as the spring-loaded switch plunger is depressed by the striker on the inner hood panel reinforcement when the hood panel is closed and latched. When the hood is opened, the spring-loaded switch plunger extends from the switch body and the switch contacts are closed. In the underhood security application (export vehicles only - dark brown retainer ring), the switch is connected in series between ground and the hood ajar switch sense input of the Totally Integrated Power Module (TIPM). The TIPM uses an internal resistor pull up to monitor the state of the hood ajar switch contacts. In the remote starter system application (domestic vehicles only - white retainer ring) the switch has a 1 kilo ohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between an output of the TIPM and the hood ajar switch sense input of the TIPM. The TIPM continually monitors this circuit and will store a Diagnostic Trouble Code (DTC) for any fault that it detects. The components of the switch self-adjustment feature include an integral stop on the shaft of the plunger and a ribbed, ratcheting sleeve-like retainer ring at the top of the switch body from which the plunger extends. With the switch mounting collar secured in its mounting bracket, the plunger is depressed by the striker on the hood inner reinforcement as the hood is closed. As the plunger is depressed, the plunger stop contacts the top of the retainer ring and it is driven downward, ratcheting through the switch mounting collar until the hood is fully closed and latched. The ribs on the retainer ring are engaged within the mounting collar to maintain this adjusted position. The hood ajar switch as well as the hard wired circuits between the switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between modules and other devices related to hood ajar switch operation that provide some features of the export vehicle theft or domestic remote starter systems. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to hood ajar switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal Hood Sensor/Switch (For Alarm): Service and Repair Removal Striker STRIKER NOTE: The hood ajar switch striker is not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Unlatch and open the hood. 2. Using a trim stick or another suitable wide flat-bladed tool, pry the rearward end of the hood ajar switch striker (2) away from the inner hood panel reinforcement (1) far enough to disengage the integral retainers from their mounting holes. 3. Remove the striker from the inner hood panel reinforcement and discard. Bracket BRACKET 1. Remove the hood ajar switch (2) from the mounting bracket (3). 2. Remove the two screws (4) that secure the hood ajar switch bracket to the two rivet nuts (1) in the right front load beam (6). 3. Remove the hood ajar switch mounting bracket from the inboard side of the right front load beam. Switch SWITCH Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal > Page 904 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. From the top of the mounting bracket (3) on the right front load beam (6), squeeze the two hood ajar switch (2) latch tabs together and pull the switch upward. 4. Pull the hood ajar switch up through the hole in the mounting bracket far enough to access and disconnect the jumper wire harness connector (5) from the switch connector receptacle. 5. Remove the hood ajar switch from the mounting bracket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal > Page 905 Hood Sensor/Switch (For Alarm): Service and Repair Installation Striker STRIKER NOTE: The hood ajar switch striker cap is not intended for reuse. If the striker cap is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Position the new hood ajar switch striker (2) to the mounting holes in the inner hood panel reinforcement (1) over the hood ajar switch (3). 2. Using hand pressure, press the hood ajar switch striker upward into the mounting holes in the inner hood panel reinforcement until both integral retainers are fully engaged. 3. Close and latch the hood. Bracket BRACKET 1. Check to be certain that the two rivet nuts (1) on the inboard side of the right front load beam (6) are in good condition and properly secured. 2. Position the hood ajar switch mounting bracket (3) onto the right front load beam. 3. Install and tighten the two screws (4) that secure the mounting bracket to the load beam. Beginning with the rearward screw, tighten both screws to 8 Nm (71 in. lbs.). 4. Reinstall the hood ajar switch (2) into the mounting bracket. Switch Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal > Page 906 SWITCH 1. Position the hood ajar switch (2) near the hole in the mounting bracket (3) on the right front load beam (6). 2. Route the jumper wire harness connector (5) through the switch mounting bracket and reconnect it to the switch connector receptacle. 3. From the top of the mounting bracket, press the switch downward into the mounting hole until the integral switch latch tabs lock it into place. 4. Reconnect the battery negative cable. 5. Close and latch the hood. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Component ID: 457 Component : SWITCH-ADJUSTABLE PEDALS Connector: Name : SWITCH-ADJUSTABLE PEDALS Color : BLUE # of pins : 6 Qualifier : (EXCEPT BASE) Pin Description Circuit 1 ADJUSTABLE PEDALS MOTOR REARWARDP206 18LG/LB 2 ADJUSTABLE PEDALS OUTPUT A72 18RD/OR 3-4 GROUND Z146 18BK 5 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 6 ADJUSTABLE PEDALS MOTOR FORWARD P205 18LG/WT Component Location - 44 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 910 Component Location - 50 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 911 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 912 Pedal Positioning Switch: Diagrams Component ID: 457 Component : SWITCH-ADJUSTABLE PEDALS Connector: Name : SWITCH-ADJUSTABLE PEDALS Color : BLUE # of pins : 6 Qualifier : (EXCEPT BASE) Pin Description Circuit 1 ADJUSTABLE PEDALS MOTOR REARWARDP206 18LG/LB 2 ADJUSTABLE PEDALS OUTPUT A72 18RD/OR 3-4 GROUND Z146 18BK 5 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 6 ADJUSTABLE PEDALS MOTOR FORWARD P205 18LG/WT Component Location - 44 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 913 Component Location - 50 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 914 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Service and Repair > Removal Pedal Positioning Switch: Service and Repair Removal REMOVAL 1. Remove the lower drivers side bezel (4). 2. Disconnect the electrical connector (3) from the adjustable pedal switch (2). 3. Remove the switch (2) from the lower drivers side bezel (4) by squeezing the retaining clips together and pushing the switch outwards. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Service and Repair > Removal > Page 917 Pedal Positioning Switch: Service and Repair Installation INSTALLATION 1. Install the switch (2) to the lower drivers side bezel (4) by pushing the switch inwards seating the retaining clips to the lower drivers side bezel (4). 2. Reconnect the electrical connector (3) to the adjustable pedal switch (2). 3. Install the lower drivers side bezel (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Switch-Door Lock-Passenger Power Door Lock Switch: Locations Switch-Door Lock-Passenger Component ID: 462 Component : SWITCH-DOOR LOCK-PASSENGER Connector: Name : SWITCH-DOOR LOCK-PASSENGER Color : NATURAL # of pins : 6 Pin Description Circuit 1 PASSENGER DOOR LOCK SWITCH MUX G160 20VT/LG 2 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 3-4-5 GROUND Z917 20BK 6-Component Location - 56 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Switch-Door Lock-Passenger > Page 922 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Switch-Door Lock-Passenger > Page 923 Power Door Lock Switch: Locations Switch-Window/Door Lock-Driver Component ID: 494 Component : SWITCH-WINDOW/DOOR LOCK-DRIVER Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C1 Color : BLUE # of pins : 12 Pin Description Circuit 1 RIGHT REAR WINDOW DRIVER (DOWN) Q612 14OR/DB 2 RIGHT REAR WINDOW DRIVER (UP) Q412 14OR/LB 3 MASTER WINDOW SWITCH RIGHT FRONT (UP) Q16 12OR/TN 4 LEFT REAR WINDOW DRIVER (UP) Q411 14OR/WT 5 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 6 MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Q26 12OR/GY 7 DRIVER DOOR LOCK SWITCH MUX G161 20VT/DG 8 GROUND Z939 12BK 9 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 12PK/YL 10 LEFT REAR WINDOW DRIVER (DOWN) Q611 14OR/GY 11 GROUND Z939 18BK 12 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Switch-Door Lock-Passenger > Page 924 Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C2 Color : BLUE # of pins : 8 Pin Description Circuit 1 LEFT MIRROR UP DRIVER P71 20TN/DG 2 LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) P195 18LG/YL 3 FUSED B(+) A940 18RD 4 RIGHT MIRROR LEFT DRIVER P74 18TN/OR 5 GROUND Z939 18BK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Switch-Door Lock-Passenger > Page 925 6 LEFT MIRROR LEFT DRIVER P75 20TN/LG 7 RIGHT MIRROR UP DRIVER P72 18TN/GY 8 POWER WINDOW SWITCH FEED Q15 12OR/LB Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger Power Door Lock Switch: Diagrams Switch-Door Lock-Passenger Component ID: 462 Component : SWITCH-DOOR LOCK-PASSENGER Connector: Name : SWITCH-DOOR LOCK-PASSENGER Color : NATURAL # of pins : 6 Pin Description Circuit 1 PASSENGER DOOR LOCK SWITCH MUX G160 20VT/LG 2 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 3-4-5 GROUND Z917 20BK 6-Component Location - 56 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger > Page 928 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger > Page 929 Power Door Lock Switch: Diagrams Switch-Window/Door Lock-Driver Component ID: 494 Component : SWITCH-WINDOW/DOOR LOCK-DRIVER Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C1 Color : BLUE # of pins : 12 Pin Description Circuit 1 RIGHT REAR WINDOW DRIVER (DOWN) Q612 14OR/DB 2 RIGHT REAR WINDOW DRIVER (UP) Q412 14OR/LB 3 MASTER WINDOW SWITCH RIGHT FRONT (UP) Q16 12OR/TN 4 LEFT REAR WINDOW DRIVER (UP) Q411 14OR/WT 5 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 6 MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Q26 12OR/GY 7 DRIVER DOOR LOCK SWITCH MUX G161 20VT/DG 8 GROUND Z939 12BK 9 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 12PK/YL 10 LEFT REAR WINDOW DRIVER (DOWN) Q611 14OR/GY 11 GROUND Z939 18BK 12 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger > Page 930 Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C2 Color : BLUE # of pins : 8 Pin Description Circuit 1 LEFT MIRROR UP DRIVER P71 20TN/DG 2 LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) P195 18LG/YL 3 FUSED B(+) A940 18RD 4 RIGHT MIRROR LEFT DRIVER P74 18TN/OR 5 GROUND Z939 18BK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger > Page 931 6 LEFT MIRROR LEFT DRIVER P75 20TN/LG 7 RIGHT MIRROR UP DRIVER P72 18TN/GY 8 POWER WINDOW SWITCH FEED Q15 12OR/LB Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Description Power Door Lock Switch: Description and Operation Description DESCRIPTION A window/lock switch is used on all models equipped with power locks, power windows, and power mirrors. The window/lock switch houses the following switches: - Power Lock Switch - A two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Mirror Selector Switch - A three-position rocker switch selects the right or left power mirror for adjustment, or turns the power mirror system Off. - Power Mirror Adjustment Switches - Four momentary, arrowhead shaped, directional switches allow the driver to adjust the selected power mirror in the Up, Down, Right, or Left directions. - Power Window Lockout Switch - A two-way, latching, push-button switch allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches. - Power Window Switches - A two-way, momentary power window switch for the driver side front door. This switch also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, there are individual master switches for each passenger door power window. The window/lock switch also incorporates several green Light-Emitting Diodes (LEDs) that illuminate the power lock and power window switch paddles, and the power mirror switch directional buttons to improve switch visibility. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Description > Page 934 Power Door Lock Switch: Description and Operation Operation OPERATION The window/lock switch combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single unit. Power Lock Switch The power lock switch circuitry is connected in series between ground and the driver door switch mux input of the instrument cluster. Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the instrument cluster input, which allows the instrument cluster to sense the switch position. Based upon the power lock switch input, the instrument cluster controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door latches. The Light-Emitting Diode (LED) in the power lock switch is connected to battery current through the power window circuit breaker in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run-acc) circuit. The switch will be illuminated whenever the ignition switch is in the On or Accessory positions. Power Window Switches The power window switch circuitry is connected to battery current through a circuit breaker in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run-acc) circuit so that the power windows will operate whenever the ignition switch is in the On or Accessory positions. Each two-way, momentary master passenger power window switch provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The switch for the driver side front door power window is labeled "Auto" and includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the master switches. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Power Mirror Switches The power mirror switch circuitry is connected to battery current through a fuse in the TIPM on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one to select the left mirror, and a neutral Off position. After the right or left mirror is selected, one of four directional buttons is depressed to move the selected mirror Up, Down, Right or Left. The power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the power mirror switch is connected to battery current through the power window circuit breaker in the TIPM on a fused ignition switch output (run-acc) circuit so that the switch directional buttons will be illuminated whenever the ignition switch is in the On or Accessory positions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Power Lock Switch Power Door Lock Switch: Testing and Inspection Power Lock Switch POWER LOCK SWITCH The Light-Emitting Diode (LED) illumination lamp of the power lock switch receives battery current through a fuse in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run) circuit. The power lock switch on the driver side front door trim panel is integral to the window/lock switch. If the power lock switch operates, but the LED is inoperative, check for battery current at the switch with the ignition switch in the On position. If OK, replace the faulty switch. Refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. Remove the power lock switch from the door trim panel. Disconnect the door wire harness connector for the power lock switch from the switch connector receptacle. 2. Test the power lock switch resistance. See the Power Lock Switch Test chart to determine if the resistance is correct for the switch in each switch position. If not OK, replace the faulty power lock switch as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Power Lock Switch > Page 937 Power Door Lock Switch: Testing and Inspection Window/Lock Switch WINDOW/LOCK SWITCH The Light-Emitting Diode (LED) illumination lamps for all of the Driver Door Module (DDM) power window, power lock, and power mirror switches receive battery current through the power window circuit breaker in the Totally Integrated Power Module (TIPM). If all of the LED's are inoperative in the DDM, be certain to diagnose the power window system before replacing the switch unit. If only one LED in the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty DDM. Refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles. 2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position. If not OK, replace the faulty DDM as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Power Lock Switch > Page 938 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Power Lock Switch > Page 939 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Removal Power Door Lock Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Removal > Page 942 Power Door Lock Switch: Service and Repair Installation INSTALLATION 1. Install switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair Power Mirror Switch: Service and Repair REMOVAL The power mirror switch is included with the window/lock switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Switch-Seat-Driver Power Seat Switch: Diagrams Switch-Seat-Driver Component ID: 484 Component : SWITCH-SEAT-DRIVER Connector: Name : SWITCH-SEAT-DRIVER Color : # of pins : 12 Qualifier : (HD) A FUSED B(+) A210 12OR/RD B GROUND Z939 14BK C-E DRIVER SEAT REAR UP DRIVER P11 12LG/YL F-G GROUND Z939 14BK H FUSED B(+) A210 12OR/RD J DRIVER SEAT REAR DOWN DRIVER P13 12LG/OR K DRIVER SEAT HORIZONTAL REARWARD DRIVER P17 12LG/DG L DRIVER SEAT HORIZONTAL FORWARD DRIVER P15 12LG/BR M DRIVER SEAT FRONT UP DRIVER P19 12LG/LB N DRIVER SEAT FRONT DOWN DRIVER P21 12LG/TN Connector: Name : SWITCH-SEAT-DRIVER Color : GRAY # of pins : 8 Qualifier : (LD) Gender : MALE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Switch-Seat-Driver > Page 950 Pin Description Circuit 1 DRIVER SEAT FRONT UP DRIVER P19 12LG/LB 2 GROUND Z939 14BK 3 DRIVER SEAT HORIZONTAL FORWARD DRIVER P15 12LG/WT 4 FUSED B(+) A210 12OR/RD 5 DRIVER SEAT REAR UP DRIVER P11 12LG/YL 6 DRIVER SEAT HORIZONTAL REARWARD DRIVER P17 12LG/DG 7 DRIVER SEAT REAR DOWN DRIVER P13 12LG/OR 8 DRIVER SEAT FRONT DOWN DRIVER P21 12LG/TN Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Switch-Seat-Driver > Page 951 Power Seat Switch: Diagrams Switch-Seat-Passenger Component ID: 485 Component : SWITCH-SEAT-PASSENGER Connector: Name : SWITCH-SEAT-PASSENGER Color : # of pins : 12 A FUSED B(+) A210 12OR/RD B GROUND Z939 14BK C-E PASSENGER SEAT REAR UP DRIVER P12 12LG/YL F-G GROUND Z939 14BK H FUSED B(+) A210 12OR/RD J PASSENGER SEAT REAR DOWN DRIVER P10 12LG/TN K PASSENGER SEAT HORIZONTAL REARWARD DRIVER P16 12LG/BR L PASSENGER SEAT HORIZONTAL FORWARD DRIVER P14 12LG/OR M PASSENGER SEAT FRONT UP DRIVER P20 12LG/LB N PASSENGER SEAT FRONT DOWN DRIVER P18 12LG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Description Power Seat Switch: Description and Operation Description DESCRIPTION The power seats on this vehicle can be adjusted in eight different directions, up, down, front up, front down, rear up, rear down, rearward and forward. The power seat switch is located on the outboard side of the seat cushion on the seat cushion side shield. The individual switches in the power seat switch assembly cannot be repaired. If one switch is damaged or inoperative, the entire power seat switch assembly must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Description > Page 954 Power Seat Switch: Description and Operation Operation OPERATION When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Page 955 Power Seat Switch: Testing and Inspection POWER SEAT SWITCH For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. 3. Using an ohmmeter to test the continuity of the power seat switches in each position. If OK Refer to Power Seat Track Testing. If not OK, replace the inoperative power seat switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Removal Power Seat Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side shield from the seat. 3. Pull the switch bezel or side shield unit (1) out from the seat far enough to access the switch wire harness connector. Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module (2). 4. Remove the screws (3) that secure the power seat switch (2) to the side shield unit (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Removal > Page 958 Power Seat Switch: Service and Repair Installation INSTALLATION 1. Position the power seat switch (2) on the seat cushion side shield (1) and install the screws (3). 2. Connect the electrical connector. 3. Install the seat cushion side shield on the seat. 4. Connect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver Seat Heater Switch: Locations Switch-Heated Seat-Driver Component ID: 467 Component : SWITCH-HEATED SEAT-DRIVER Connector: Name : SWITCH-HEATED SEAT-DRIVER Color : DK. GRAY # of pins : 6 Pin Description Circuit 1 GROUND Z301 20TN/BK 2 PANEL LAMPS DRIVER P301 20LG/OR 3 DRIVER SEAT HEATER SUPPLY P693 18LG/WT 4 FUSED B(+) A930 16RD 5-6 FUSED B(+) A930 16RD Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver > Page 963 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver > Page 964 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver > Page 965 Seat Heater Switch: Locations Switch-Heated Seat-Passenger Component ID: 468 Component : SWITCH-HEATED SEAT-PASSENGER Connector: Name : SWITCH-HEATED SEAT-PASSENGER Color : GREEN # of pins : 6 Pin Description Circuit 1 GROUND Z302 20LG/BK 2 PANEL LAMPS DRIVER P301 20LG/OR 3 PASSENGER SEAT HEATER SUPPLY P95 18LG/WT 4 FUSED B(+) A930 16RD 5-6 FUSED B(+) A930 16RD Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver > Page 966 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver > Page 967 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver Seat Heater Switch: Diagrams Switch-Heated Seat-Driver Component ID: 467 Component : SWITCH-HEATED SEAT-DRIVER Connector: Name : SWITCH-HEATED SEAT-DRIVER Color : DK. GRAY # of pins : 6 Pin Description Circuit 1 GROUND Z301 20TN/BK 2 PANEL LAMPS DRIVER P301 20LG/OR 3 DRIVER SEAT HEATER SUPPLY P693 18LG/WT 4 FUSED B(+) A930 16RD 5-6 FUSED B(+) A930 16RD Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver > Page 970 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver > Page 971 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver > Page 972 Seat Heater Switch: Diagrams Switch-Heated Seat-Passenger Component ID: 468 Component : SWITCH-HEATED SEAT-PASSENGER Connector: Name : SWITCH-HEATED SEAT-PASSENGER Color : GREEN # of pins : 6 Pin Description Circuit 1 GROUND Z302 20LG/BK 2 PANEL LAMPS DRIVER P301 20LG/OR 3 PASSENGER SEAT HEATER SUPPLY P95 18LG/WT 4 FUSED B(+) A930 16RD 5-6 FUSED B(+) A930 16RD Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver > Page 973 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver > Page 974 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Description Seat Heater Switch: Description and Operation Description DESCRIPTION Momentary contact push button switch/modules mounted in the instrument panel center bezel operate the heated seat system. Each heated seat switch/module has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected level (Low or High) of the seat heater. Pressing the switch/module button initiates heat. Heat remains on until switched off or until the ignition is turned off. If switched off by the ignition, a switch/module button must be pressed to restart heating. The switch/modules contain the solid state electronic control and diagnostic logic circuitry for the heated seat system. If any of the heated seat elements are inoperative or damaged one or more of the LED lamps in the switch/module for the effected seat will flash. The LED indicator lamps in each heated seat switch/module cannot be repaired. If the LED lamps are faulty or damaged, or the switch/module is inoperative or damaged the individual heated seat switch/module assembly must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Description > Page 977 Seat Heater Switch: Description and Operation Operation OPERATION A Heated Seat Switch/Module is used to control the heated seat system. The heated seat switch/modules receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The switch/module responds to heated seat switch/module button input and ignition switch status inputs by controlling the 12v output to the front seat heating elements through integral solid-state relays. When either of the heated seat switch/module buttons are depressed the heating element for the selected seat is energized. Amber Light Emitting Diodes (LEDS) on the side of each switch/module indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. Pressing the switch/module button once will select high-level heating. Pressing the button a second time will select low-level heating. Pressing the button a third time will shut the heating elements off. The heated seat switch/module energizes an integral solid-state relay, which supplies battery current to the heating elements. When high-temperature heating is selected, the heaters provide a boosted heat level during the first four minutes of operation after heating is activated. The heat output then drops to the normal high-temperature level. If high-level heating is selected, the control system will automatically switch to the low level after two hours of continuous operation. At that time, the number of illuminated LEDs changes from two to one, indicating the change. Operation on the low setting will continue indefinitely until the switch/module button is pushed to turn the system off. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Removal Seat Heater Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. 3. Disconnect the switch/module electrical connectors. 4. Using an appropriate flat bladed tool, remove the heated seat switch/module from the bezel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Removal > Page 980 Seat Heater Switch: Service and Repair Installation INSTALLATION 1. Align the tabs of the switch/module to the instrument panel center bezel and gently push together until the tabs are securely in place. 2. Connect the switch/module electrical connectors. 3. Install the instrument panel center bezel. 4. Connect the battery negative cable. 5. Verify heated seat system operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Sunroof / Moonroof Switch: Locations Component ID: 489 Component : SWITCH-SUNROOF Connector: Name : SWITCH-SUNROOF Color : BLACK # of pins : 4 A SUNROOF VENT SWITCH SENSE Q4 20OR/YL B SUNROOF SWITCH SUPPLY Q6 20OR/LG C SUNROOF OPEN SWITCH SENSE Q3 20OR/TN D SUNROOF CLOSE SWITCH SENSE Q5 20OR/LB Component Location - 53 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 984 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 985 Sunroof / Moonroof Switch: Diagrams Component ID: 489 Component : SWITCH-SUNROOF Connector: Name : SWITCH-SUNROOF Color : BLACK # of pins : 4 A SUNROOF VENT SWITCH SENSE Q4 20OR/YL B SUNROOF SWITCH SUPPLY Q6 20OR/LG C SUNROOF OPEN SWITCH SENSE Q3 20OR/TN D SUNROOF CLOSE SWITCH SENSE Q5 20OR/LB Component Location - 53 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 986 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Description Sunroof / Moonroof Switch: Description and Operation Description DESCRIPTION The power sunroof switch (3) is a combination push-button and rocker switch module mounted in the overhead console. The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/module assembly. The sunroof switch performs the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed) The power sunroof switch is part of the overhead console assembly and cannot be replaced separately. If the switch is damaged or inoperative the overhead console must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Description > Page 989 Sunroof / Moonroof Switch: Description and Operation Operation OPERATION The power sunroof switch is hard wired to the sunroof motor/module assembly. The switch receives battery current from the motor/module when the ignition switch is in the RUN and ACCESSORY positions. When one of the switch positions is pressed it sends battery current back to the motor/module, signaling it to move the power sunroof to the appropriate position. The motor/module will perform one of the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Page 990 Sunroof / Moonroof Switch: Testing and Inspection SWITCH - POWER SUNROOF For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. If completing the appropriate diagnostic information results in the sunroof switch being inoperative, perform the following test prior to switch replacement. 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console. 3. Disconnect the power sunroof switch wire harness connector. 4. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. Refer to the POWER SUNROOF SWITCH CONTINUITY TABLE. If OK, inspect the wiring harness and connectors for damage. Use a scan tool and the proper Diagnostic Procedures Information to complete diagnosis of the power sunroof system. If not OK, replace the overhead console. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Component ID: 389 Component : SENSOR-BRAKE FLUID LEVEL Connector: Name : SENSOR-BRAKE FLUID LEVEL Color : BLACK # of pins : 2 Pin Description Circuit 1 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/OR 2 GROUND Z420 20BK/OR Component Location - 32 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 995 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 996 Brake Fluid Level Sensor/Switch: Diagrams Component ID: 389 Component : SENSOR-BRAKE FLUID LEVEL Connector: Name : SENSOR-BRAKE FLUID LEVEL Color : BLACK # of pins : 2 Pin Description Circuit 1 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/OR 2 GROUND Z420 20BK/OR Component Location - 32 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 997 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations Lateral Accelerometer: Locations Component ID: 393 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : # of pins : 6 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/GY 3 DYNAMICS SENSOR LOW DATA LINK D464 20WT/OR 4-5-6 GROUND Z608 20BK/LG Component Location - 52 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 1001 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 1002 Lateral Accelerometer: Diagrams Component ID: 393 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : # of pins : 6 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/GY 3 DYNAMICS SENSOR LOW DATA LINK D464 20WT/OR 4-5-6 GROUND Z608 20BK/LG Component Location - 52 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 1003 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 1004 Lateral Accelerometer: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor. The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Removal Lateral Accelerometer: Service and Repair Removal REMOVAL 1. Remove the center bezel lower trim panel. 2. Remove the cup holder. 3. Disconnect the electrical connector (3) for the dynamics sensor (2). 4. Remove the 3 mounting nuts (1) for the sensor (2). 5. Remove the sensor (2) from the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Removal > Page 1007 Lateral Accelerometer: Service and Repair Installation INSTALLATION 1. Install the dynamics sensor on the mounting studs (2). 2. Install the mounting nuts (1) Tighten to 24 Nm (200 in. lbs.). 3. Reconnect the electrical connector (3). 4. Install the cup holder. 5. Install the center bezel lower trim panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Component ID: 474 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : GRAY # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 1011 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 1012 Parking Brake Warning Switch: Diagrams Component ID: 474 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : GRAY # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 1013 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Description Parking Brake Warning Switch: Description and Operation Description DESCRIPTION The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Description > Page 1016 Parking Brake Warning Switch: Description and Operation Operation OPERATION The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Page 1017 Parking Brake Warning Switch: Testing and Inspection PARK BRAKE SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: If the brake indicator stays ON with the ignition switch in the ON position and the park brake released, or comes ON while driving, the brake system must be diagnosed and repaired prior to performing the following tests. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an ineffective park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to STEP 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OKAY 3. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to STEP 2. If not OK, replace the ineffective park brake switch. 4. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair > Removal Parking Brake Warning Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair > Removal > Page 1020 Parking Brake Warning Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Reach under the left end of the instrument panel to position the park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 Nm (24 in. lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. 5. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set Steering Angle Sensor: Customer Interest ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set NUMBER: 08-044-06 GROUP: Electrical DATE: October 07, 2006 SUBJECT: DTC C1240 - Steering Angle Sensor Over Travel Performance OVERVIEW: This bulletin involves the diagnosis and possible replacement of the Steering Angle Sensor. MODELS: 2007 (DR) Ram Truck NOTE: This bulletin applies to vehicle equipped with the Electronic Stability Program (sales code BNB) and built prior to October 03, 2006 (MDH 1003XX). SYMPTOM/CONDITION: The customer may experience an illumination on the instrument cluster of the "ABS" (Anti-Lock Brake System) and/or the "ESP / BAS" (Electronic Stability Program / Brake Assist System) Warning Lights. Investigation may reveal the presence of Diagnostic Trouble Code (DTC) C1240 Steering Angle Sensor Over Travel Performance (SAS). DIAGNOSIS: 1. Perform the diagnostic test procedure for DTC C1240. This diagnostic procedure can be found on TechCONNECT: select the SERVICE INFO tab > 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 340/445E5P AWAL > DIAGNOSIS and TESTING > C1240 - Steering Angle Sensor Over Travel Performance (SAS). 2. If the diagnostic test procedure for DTC C1240 determines that the Steering Angle Sensor is at fault, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Before starting this procedure, be certain that the front wheels are in the straight-ahead position. 1. Replace the steering column clockspring. Refer to TechCONNECT for detailed service procedures: select the SERVICE INFO tab > 8 - ELECTRICAL > RESTRAINTS > CLOCKSPRING > REMOVAL and INSTALLATION. 2. Clear offsets by initializing the ABS ECU using StarSCAN. 3. Perform the ABS VERIFICATION TEST. This test can be found in: 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 3401445E5P AWAL > STANDARD PROCEDURE > ABS VERIFICATION TEST. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set > Page 1029 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set Steering Angle Sensor: All Technical Service Bulletins ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set NUMBER: 08-044-06 GROUP: Electrical DATE: October 07, 2006 SUBJECT: DTC C1240 - Steering Angle Sensor Over Travel Performance OVERVIEW: This bulletin involves the diagnosis and possible replacement of the Steering Angle Sensor. MODELS: 2007 (DR) Ram Truck NOTE: This bulletin applies to vehicle equipped with the Electronic Stability Program (sales code BNB) and built prior to October 03, 2006 (MDH 1003XX). SYMPTOM/CONDITION: The customer may experience an illumination on the instrument cluster of the "ABS" (Anti-Lock Brake System) and/or the "ESP / BAS" (Electronic Stability Program / Brake Assist System) Warning Lights. Investigation may reveal the presence of Diagnostic Trouble Code (DTC) C1240 Steering Angle Sensor Over Travel Performance (SAS). DIAGNOSIS: 1. Perform the diagnostic test procedure for DTC C1240. This diagnostic procedure can be found on TechCONNECT: select the SERVICE INFO tab > 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 340/445E5P AWAL > DIAGNOSIS and TESTING > C1240 - Steering Angle Sensor Over Travel Performance (SAS). 2. If the diagnostic test procedure for DTC C1240 determines that the Steering Angle Sensor is at fault, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Before starting this procedure, be certain that the front wheels are in the straight-ahead position. 1. Replace the steering column clockspring. Refer to TechCONNECT for detailed service procedures: select the SERVICE INFO tab > 8 - ELECTRICAL > RESTRAINTS > CLOCKSPRING > REMOVAL and INSTALLATION. 2. Clear offsets by initializing the ABS ECU using StarSCAN. 3. Perform the ABS VERIFICATION TEST. This test can be found in: 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 3401445E5P AWAL > STANDARD PROCEDURE > ABS VERIFICATION TEST. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set > Page 1035 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Page 1036 Steering Angle Sensor: Locations Component ID: 425 Component : SENSOR-STEERING ANGLE Connector: Name : SENSOR-STEERING ANGLE Color : BLACK # of pins : 4 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/LG 2 GROUND Z455 20BK/PK 3 CAN C BUS (-) D64 20WT/LB 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Page 1037 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Page 1038 Steering Angle Sensor: Diagrams Component ID: 425 Component : SENSOR-STEERING ANGLE Connector: Name : SENSOR-STEERING ANGLE Color : BLACK # of pins : 4 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/LG 2 GROUND Z455 20BK/PK 3 CAN C BUS (-) D64 20WT/LB 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Page 1039 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations Traction Control Switch: Locations Component ID: 463 Component : SWITCH-ESP Connector: Name : SWITCH-ESP Color : # of pins : 6 Pin Description Circuit 1 GROUND Z936 20BK/DG 2 PANEL LAMPS DRIVER E11 20OR/DB 3 ESP ON/OFF SENSE B46 20DG/WT 4 SENSOR GROUND G94 20VT/DB 5-6-Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 1043 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 1044 Traction Control Switch: Diagrams Component ID: 463 Component : SWITCH-ESP Connector: Name : SWITCH-ESP Color : # of pins : 6 Pin Description Circuit 1 GROUND Z936 20BK/DG 2 PANEL LAMPS DRIVER E11 20OR/DB 3 ESP ON/OFF SENSE B46 20DG/WT 4 SENSOR GROUND G94 20VT/DB 5-6-Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 1045 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 1046 Traction Control Switch: Description and Operation DESCRIPTION The ESP switch is located just below the heater and air conditioner controls in the center stack area of the instrument panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Removal Traction Control Switch: Service and Repair Removal REMOVAL 1. Remove the radio trim panel (1). 2. Disconnect the electrical connectors from the radio trim panel. 3. Remove the ESP switch (1) from the switch bank (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Removal > Page 1049 Traction Control Switch: Service and Repair Installation INSTALLATION 1. Install the new switch (1) in the switch bank (2). 2. Reconnect the electrical connectors for the radio trim panel. 3. Install the radio trim panel (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Left Front Component ID: 434 Component : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Color : # of pins : 2 Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR (+) B9 20DG/LG Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR (+) B9 18DG/LG 2 LEFT FRONT WHEEL SPEED SENSOR (-) B8 20DG/TN 2 LEFT FRONT WHEEL SPEED SENSOR (-) B8 18DG/TN Component Location - 38 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 1054 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 1055 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Rear Component ID: 436 Component : SENSOR-WHEEL SPEED-ABS-REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-REAR Color : BLACK # of pins : 2 Qualifier : (EXCEPT ESP) Pin Description Circuit 1 REAR WHEEL SPEED SENSOR (-) B22 18DG/YL 2 REAR WHEEL SPEED SENSOR (+) B222 18DG/WT Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 1056 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 1057 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Left Rear Component ID: 435 Component : SENSOR-WHEEL SPEED-ABS-LEFT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT REAR Color : # of pins : 2 Qualifier : (ESP) Pin Description Circuit 1 REAR WHEEL SPEED SENSOR (-) B3 18DG/YL 2 REAR WHEEL SPEED SENSOR (+) B4 18DG/GY Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 1058 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 1059 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Right Front Component ID: 437 Component : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Color : # of pins : 2 Pin Description Circuit 1 RIGHT FRONT WHEEL SPEED SENSOR (+) B7 20DG/VT 2 RIGHT FRONT WHEEL SPEED SENSOR (-) B6 20DG/WT Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 1060 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 1061 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Right Rear Component ID: 438 Component : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Color : # of pins : 2 Qualifier : (ESP) Pin Description Circuit 1 RIGHT REAR WHEEL SPEED SENSOR (-) B1 18DG/OR 2 RIGHT REAR WHEEL SPEED SENSOR (+) B2 18DG/LB Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 1062 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Left Front Component ID: 434 Component : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Color : # of pins : 2 Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR (+) B9 20DG/LG Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR (+) B9 18DG/LG 2 LEFT FRONT WHEEL SPEED SENSOR (-) B8 20DG/TN 2 LEFT FRONT WHEEL SPEED SENSOR (-) B8 18DG/TN Component Location - 38 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 1065 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 1066 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Rear Component ID: 436 Component : SENSOR-WHEEL SPEED-ABS-REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-REAR Color : BLACK # of pins : 2 Qualifier : (EXCEPT ESP) Pin Description Circuit 1 REAR WHEEL SPEED SENSOR (-) B22 18DG/YL 2 REAR WHEEL SPEED SENSOR (+) B222 18DG/WT Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 1067 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 1068 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Left Rear Component ID: 435 Component : SENSOR-WHEEL SPEED-ABS-LEFT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT REAR Color : # of pins : 2 Qualifier : (ESP) Pin Description Circuit 1 REAR WHEEL SPEED SENSOR (-) B3 18DG/YL 2 REAR WHEEL SPEED SENSOR (+) B4 18DG/GY Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 1069 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 1070 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Right Front Component ID: 437 Component : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Color : # of pins : 2 Pin Description Circuit 1 RIGHT FRONT WHEEL SPEED SENSOR (+) B7 20DG/VT 2 RIGHT FRONT WHEEL SPEED SENSOR (-) B6 20DG/WT Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 1071 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 1072 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Right Rear Component ID: 438 Component : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Color : # of pins : 2 Qualifier : (ESP) Pin Description Circuit 1 RIGHT REAR WHEEL SPEED SENSOR (-) B1 18DG/OR 2 RIGHT REAR WHEEL SPEED SENSOR (+) B2 18DG/LB Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 1073 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Description Wheel Speed Sensor: Description and Operation Description DESCRIPTION The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front hub/bearings. The third sensor is mounted on top of the rear axle differential housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Description > Page 1076 Wheel Speed Sensor: Description and Operation Operation OPERATION The Wheel Speed Sensor consists of a magnet (1) surrounded by windings from a single strand of wire (5). The sensor sends a small AC signal to the ABM. This signal is generated by magnetic induction. The magnetic induction is created when a toothed sensor ring (exciter ring or tone wheel) (4) passes the stationary magnetic WSS. When the ring gear is rotated, the exciter ring (4) passes the tip of the WSS. As the exciter ring tooth approaches the tip of the WSS, the magnetic lines of force expand, causing the magnetic field to cut across the sensor's windings (5). This, in turn causes current to flow through the WSS circuit in one direction. When the exciter ring tooth moves away from the sensor tip, the magnetic lines of force collapse cutting the winding in the opposite direction. This causes the current to flow in the opposite direction. Every time a tooth of the exciter ring passes the tip of the WSS, an AC signal is generated current. Each AC signal (positive to negative signal or squarewave) is interpreted by the ABM. It then compares the frequency of the sinewave to a time value to calculate vehicle speed. The ABM continues to monitor the frequency to determine a deceleration rate that would indicate a possible wheel-locking tendency. The signal strength of any magnetic induction sensor is directly affected by: - Magnetic field strength; the stronger the magnetic field, the stronger the signal - Number of windings in the sensor; more windings provide a stronger signal - Exciter ring speed; the faster the exciter ring/tone wheel rotates, the stronger the signal will be - Distance (3) "air gap" between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring/tone wheel, the stronger the signal will be. The WSS is not adjustable. A clearance specification has been established for manufacturing tolerances. If the clearance is not within these specifications, then either the WSS or other components may be damaged. The clearance between the WSS and the exciter ring is 0.005 0.050 in. The assembly plant performs a "Rolls Test" on every vehicle that leaves the assembly plant. One of the test performed is a test of the WSS. To properly test the sensor, the assembly plant connects test equipment to the Data Link Connector (DLC). This connector is located to the right of the steering column and attached to the lower portion of the instrument panel. The rolls test terminal is spliced to the WSS circuit. The vehicle is then driven on a set of rollers and the WSS output is monitored for proper operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Page 1077 Wheel Speed Sensor: Testing and Inspection REAR WHEEL ANTILOCK Diagnosis of base brake conditions which are mechanical in nature should be performed first. This includes brake noise, lack of power assist, parking brake, or vehicle vibration during normal braking. The RWAL brake system performs several self-tests every time the ignition switch is turned on and the vehicle is driven. The CAB monitors the system inputs and outputs circuits to verify the system is operating properly. If the CAB senses a malfunction in the system it will set a DTC into memory and trigger the warning lamp. NOTE: A scan tool is used to diagnose the RWAL system. For test procedures refer to the ABS Electrical Diagnostic. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor- Wheel Speed-ABS-Front Wheel Speed Sensor: Service and Repair Sensor- Wheel Speed-ABS-Front Removal REMOVAL 1. Remove the front rotor. 2. Remove the wheel speed sensor mounting bolt (1) from the hub (3). 3. Remove the wheel speed sensor (2) from the hub (3). 4. Remove the wiring from the clips and disconnect the electrical connector. Installation INSTALLATION 1. Install the wiring to the clips and Reconnect the electrical connector. 2. Install the wheel speed sensor (2) to the hub (3). 3. Install the wheel speed sensor mounting bolt (1) to the hub (3). Tighten the bolt to 21 Nm (190 in. lbs.). 4. Install the front rotor and brake caliper assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor- Wheel Speed-ABS-Front > Page 1080 Wheel Speed Sensor: Service and Repair Sensor-Wheel Speed-ABS-Rear Removal REMOVAL 1. Raise the vehicle on a hoist. 2. Remove the brake line mounting nut and remove the brake line from the sensor stud. 3. Remove the mounting stud (2) from the sensor and shield. 4. Remove the sensor (1) and shield from the differential housing (3). 5. Disconnect the sensor wire harness and remove the sensor (1). Installation INSTALLATION 1. Connect the harness to the sensor. Be sure the seal is securely in place between the sensor and the wiring connector. 2. Install the O-ring on the sensor (if removed). 3. Insert the sensor (1) in the differential housing (3). 4. Install the sensor shield. 5. Install the sensor mounting stud (2) and tighten to 24 Nm (200 in. lbs.). 6. Install the brake line on the sensor stud (2)and install the nut. 7. Lower the vehicle. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor- Wheel Speed-ABS-Front > Page 1081 1. Raise the vehicle on a hoist. 2. Disconnect the wheel speed sensor electrical connector (3). 3. Remove the mounting bolt (1) from the sensor (4). 4. Remove the sensor (4) from the brake caliper adapter (2). Installation INSTALLATION 1. Insert the wheel speed sensor (4) in the brake caliper adapter (2). 2. Install the sensor mounting bolt (1) and tighten to 24 Nm (200 in. lbs.). 3. Reconnect the electrical wiring connector (3) to the sensor (4). 4. Lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations Yaw Rate Sensor: Locations Component ID: 393 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : # of pins : 6 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/GY 3 DYNAMICS SENSOR LOW DATA LINK D464 20WT/OR 4-5-6 GROUND Z608 20BK/LG Component Location - 52 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 1085 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 1086 Yaw Rate Sensor: Diagrams Component ID: 393 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : # of pins : 6 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/GY 3 DYNAMICS SENSOR LOW DATA LINK D464 20WT/OR 4-5-6 GROUND Z608 20BK/LG Component Location - 52 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 1087 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 1088 Yaw Rate Sensor: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor. The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Removal Yaw Rate Sensor: Service and Repair Removal REMOVAL 1. Remove the center bezel lower trim panel. 2. Remove the cup holder. 3. Disconnect the electrical connector (3) for the dynamics sensor (2). 4. Remove the 3 mounting nuts (1) for the sensor (2). 5. Remove the sensor (2) from the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Removal > Page 1091 Yaw Rate Sensor: Service and Repair Installation INSTALLATION 1. Install the dynamics sensor on the mounting studs (2). 2. Install the mounting nuts (1) Tighten to 24 Nm (200 in. lbs.). 3. Reconnect the electrical connector (3). 4. Install the cup holder. 5. Install the center bezel lower trim panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Description Coolant Temperature Sensor/Switch (For Computer): Description and Operation Description DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Description > Page 1098 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Operation OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air-fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: - for engine coolant temperature gauge operation through CAN Bus communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid on/off times - Cooling fan control - Temperature gauge operation - A/C cutoff at high coolant temperatures - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Removal Coolant Temperature Sensor/Switch (For Computer): Service and Repair Removal 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL WARNING: Hot, pressurized coolant can cause injury by scalding. Cooling system must be partially drained before removing the coolant temperature sensor. 1. Partially drain the cooling system. ECT LOCATION - 5.9L DIESEL 2. Remove heat shield (if equipped). 3. Disconnect the electrical connector (2) from the ETC sensor (3). 4. Remove the ETC sensor from the cylinder head. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Removal > Page 1101 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Installation 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL 1. Install sensor (1 or 3) to engine. 2. Tighten sensor to 18 Nm (13 ft. lbs.) torque. ECT LOCATION - 5.9L DIESEL 3. Connect electrical connector (2) to ETC sensor (1 or 3). 4. Install heat shield (if equipped). 5. Replace any lost engine coolant. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Switch-Speed Control-Left Cruise Control Switch: Diagrams Switch-Speed Control-Left Component ID: 486 Component : SWITCH-SPEED CONTROL-LEFT Connector: Name : SWITCH-SPEED CONTROL-LEFT Color : BLACK # of pins : 3 A S/C SWITCH NO. 2 SIGNAL V38 22VT/OR B S/C SWITCH RETURN V937 22DB/DG B SENSOR GROUND K900 22DB/DG C S/C SWITCH NO. 1 SIGNAL V37 22VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Switch-Speed Control-Left > Page 1107 Cruise Control Switch: Diagrams Switch-Speed Control-Right Component ID: 487 Component : SWITCH-SPEED CONTROL-RIGHT Connector: Name : SWITCH-SPEED CONTROL-RIGHT Color : BLACK # of pins : 3 A S/C SWITCH NO. 2 SIGNAL V38 22VT/OR B S/C SWITCH RETURN V937 22DB/DG B SENSOR GROUND K900 22DB/DG C S/C SWITCH NO. 1 SIGNAL V37 22VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Description Cruise Control Switch: Description and Operation Description DESCRIPTION Two separate switch pods operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM (to the ECM for diesel) for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the Owner's Manual for speed control switch functions and setting procedures. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Depending on engine control computer (JTEC having a 3- plug connector or NGC having a 4- plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switch used with the NGC system has an attached pigtail lead. The switch used with the JTEC system does not have an attached pigtail lead. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Description > Page 1110 Cruise Control Switch: Description and Operation Operation OPERATION When speed control is selected by depressing the ON, OFF switch, the PCM (ECM for diesel) allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 (56.2kph) and 85 mph (136.8kph). In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: - Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: - An indication of Park or Neutral (auto. trans.) - The VSS signal increases at a rate of 10 mph (16 kph) per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - Depressing the clutch pedal (manual trans.). - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph (16 kph) per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph (32.1 kph) of the set speed - The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM (ECM for diesel). NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's/ECM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM (ECM for diesel) is programmed for an acceleration feature. With the ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the PCM's/ECM's RAM when the ACCEL switch is released. The PCM/ECM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph (3.2 kph) for each momentary switch activation of the ACCEL switch. The PCM/ECM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached. Then release the switch. The ON, OFF switch operates two components: the PCM's/ECM's ON, OFF input, and the battery voltage to the brake switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Removal Cruise Control Switch: Service and Repair Removal REMOVAL Depending on engine control computer (JTEC having a 3-plug connector or 5.7L V-8 NGC having a 4-plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switches used with the NGC system have attached pigtail leads . The switch used with the JTEC system does not have an attached pigtail lead. 1. Remove switch mounting screw (2). 2. Pull switch (2) from steering wheel. 3. Unplug electrical connector from switch, or, if equipped, switch pigtail wire harness from steering wheel wire harness (4) and remove switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Removal > Page 1113 Cruise Control Switch: Service and Repair Installation INSTALLATION 1. Plug electrical connector into switch, or, if equipped, connect pigtail wire harness to steering wheel wire harness. Be sure wires are not pinched. 2. Position switch to steering wheel. 3. Install switch mounting screw and tighten 15 in. lbs. ( 1.7 Nm). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Component ID: 473 Component : SWITCH-OIL PRESSURE Connector: Name : SWITCH-OIL PRESSURE Color : BLACK # of pins : 2 Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 18VT/GY Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 16VT/GY 2-Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1118 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1119 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1120 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1121 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1122 Oil Pressure Sender: Diagrams Component ID: 473 Component : SWITCH-OIL PRESSURE Connector: Name : SWITCH-OIL PRESSURE Color : BLACK # of pins : 2 Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 18VT/GY Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 16VT/GY 2-Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1123 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1124 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1125 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1126 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Removal Oil Pressure Sender: Service and Repair Removal REMOVAL NOTE: When installing a new oil pressure switch, the kit will include a special 90° fitting that must be installed. Clock the fitting and switch assembly between the 1:00 o'clock and 2:00 o'clock position. Torque the fitting bolt to 18 Nm (13 ft. lbs) 1. Disconnect the battery negative cables. 2. Disconnect the oil pressure switch connector. 3. Using a suitable socket, remove the oil pressure switch from the block (counter-clockwise). 4. Remove the banjo screw from the oil pressure switch mounting block. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Removal > Page 1129 Oil Pressure Sender: Service and Repair Installation INSTALLATION 1. Install banjo screw through the oil pressure switch mounting block. The switch mounting block port (oil switch port) should point to the 2 o'clock position. Torque the banjo screw to 24 Nm or 18 ft lbs. 2. If the switch is not being replaced, replace and lubricate the o-ring. 3. Install the oil pressure switch and tighten to 18 Nm (159 in. lbs.) torque. 4. Connect oil pressure switch connector. 5. Connect the battery negative cables. 6. Start engine and check for oil leaks at the switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1134 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1135 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1136 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1137 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1138 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1139 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1140 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1141 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1142 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1143 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1144 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1145 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1146 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1147 Oil Pressure Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1148 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1149 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1150 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1151 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1157 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1158 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1159 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1160 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1161 Component Location - 25 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1162 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1165 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1166 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1167 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1168 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1169 Component Location - 25 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1170 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1175 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1176 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1177 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1178 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1179 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1180 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1181 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1182 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1185 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1186 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1187 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1188 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1189 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1190 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1191 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1192 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 1195 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 1198 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations Component ID: 387 Component : SENSOR-AMBIENT AIR TEMPERATURE Connector: Name : SENSOR-AMBIENT AIR TEMPERATURE Color : BLACK # of pins : 2 Pin Description Circuit 1 AAT SIGNAL G31 20VT/LG 2 AAT RETURN G930 20VT/TN Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 1203 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 1204 Ambient Temperature Sensor / Switch HVAC: Diagrams Component ID: 387 Component : SENSOR-AMBIENT AIR TEMPERATURE Connector: Name : SENSOR-AMBIENT AIR TEMPERATURE Color : BLACK # of pins : 2 Pin Description Circuit 1 AAT SIGNAL G31 20VT/LG 2 AAT RETURN G930 20VT/TN Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 1205 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Description Ambient Temperature Sensor / Switch HVAC: Description and Operation Description DESCRIPTION The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the left side of the radiator yoke, behind the radiator grille and in front of the engine compartment. The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Description > Page 1208 Ambient Temperature Sensor / Switch HVAC: Description and Operation Operation OPERATION The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent by the Totally Integrated Power Module (TIPM). The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the TIPM. Based upon the resistance in the sensor, the TIPM senses a specific voltage on the temperature sensor signal circuit. The TIPM then translates the voltage into a temperature reading that it sent over the Programmable Communications Interface (PCI) data bus circuit to other modules utilizing temperature information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Page 1209 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection AMBIENT TEMPERATURE SENSOR The temperature function is supported by the ambient temperature sensor, a wiring circuit, and the Totally Integrated Power Module (TIPM). When the sensor is exposed to temperatures above 60° C (140° F), or if the sensor circuit is shorted, 60° C (130/140° F) will appear in the display in place of the temperature. When the sensor is exposed to temperatures below - 40° C (- 40° F) or if the sensor circuit is open, - 40° C (- 40° F) will appear in the display for Compass Mini - Trip Computer (CMTC) equipped vehicles and - -° C (- -° F) will be displayed on Electronic Vehicle Information Center (EVIC) equipped vehicles. The ambient temperature sensor circuit can be diagnosed using the following Temperature System Test, and Sensor Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, test the Compass Mini - Trip Computer (CMTC) or Electronic Vehicle Information Center (EVIC) as applicable. TEMPERATURE SYSTEM TEST For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. NOTE: Temperature readings do not update immediately. Allow up to 60 seconds after the ignition switch is turned to the On position for readings to meet test specifications. 1. Turn the ignition switch to the Off position. Disconnect the wire harness connector from the ambient temperature sensor. 2. Turn the ignition switch to the On position. The CMTC display should now read - 40° C (- 40° F) or the EVIC display should now read - -° C (- ° F). If OK, go to STEP 3. If not OK, repair the shorted sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 3. Turn the ignition switch to the Off position. Taking care not to damage the wire terminals, connect a jumper wire between the two terminals in the body half of the ambient temperature sensor harness connector. 4. Turn the ignition switch to the On position. The CMTC or EVIC display should now read 60° C (130/140° F). If OK, go to STEP 5. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 5. Clear any Diagnostic Trouble Codes that may have been set while performing the test. Perform further diagnosis of the Compass Mini - Trip Computer (CMTC) or Electronic Vehicle Information Center (EVIC) as applicable. SENSOR TEST 1. Turn the ignition switch to the Off position. Disconnect the ambient temperature sensor harness connector. 2. Measure the resistance of the ambient temperature sensor. At - 40° C (- 40° F), the sensor resistance is 336 kilohms. At 55° C (130° F), the sensor resistance is 2.488 kilohms. The sensor resistance should read between these two values. If OK, perform further diagnosis of the Compass Mini - Trip Computer (CMTC) or Electronic Vehicle Information Center (EVIC) as applicable. If not OK, replace the inoperative ambient temperature sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Service and Repair > Removal Ambient Temperature Sensor / Switch HVAC: Service and Repair Removal REMOVAL 1. Open the hood. 2. Disconnect and isolate the battery negative cable. 3. Working on the underside of the hood, remove screw holding sensor to hood panel. 4. Disconnect the sensor electrical connector and remove sensor from vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Service and Repair > Removal > Page 1212 Ambient Temperature Sensor / Switch HVAC: Service and Repair Installation INSTALLATION 1. Connect the sensor electrical connector. 2. Working on the underside of the hood, install screw holding sensor to hood panel. 3. Connect the battery negative cable. 4. Close the hood. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations Component ID: 396 Component : SENSOR-EVAPORATOR TEMPERATURE Connector: Name : SENSOR-EVAPORATOR TEMPERATURE Color : NATURAL # of pins : 2 Pin Description Circuit 1 SENSOR GROUND C121 20DB/DG 2 EVAPORATOR TEMPERATURE SENSOR SIGNAL C21 20DB/LG Component Location - 40 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 1216 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 1217 Evaporator Temperature Sensor / Switch: Diagrams Component ID: 396 Component : SENSOR-EVAPORATOR TEMPERATURE Connector: Name : SENSOR-EVAPORATOR TEMPERATURE Color : NATURAL # of pins : 2 Pin Description Circuit 1 SENSOR GROUND C121 20DB/DG 2 EVAPORATOR TEMPERATURE SENSOR SIGNAL C21 20DB/LG Component Location - 40 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 1218 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Description Evaporator Temperature Sensor / Switch: Description and Operation Description DESCRIPTION NOTE: Cutaway of HVAC housing shown for clarity. The evaporator temperature sensor (1) is an electrical thermistor located within a molded plastic case that is inserted into the top of the HVAC housing (2) to measure the temperature of the conditioned air downstream of the A/C evaporator (3). Two terminals within the connector receptacle connect the sensor to the vehicle electrical system through a wire lead and connector of the HVAC wire harness. The external location of the evaporator temperature sensor allows the sensor to be removed or installed without disturbing the refrigerant in the A/C system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Description > Page 1221 Evaporator Temperature Sensor / Switch: Description and Operation Operation OPERATION The evaporator temperature sensor monitors the temperature of the conditioned air downstream of the A/C evaporator and supplies an input signal to the A/C-heater control. The A/C-heater control uses the evaporator temperature sensor input signal to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor will change its internal resistance in response to the temperatures it monitors and is connected to the A/C-heater control through sensor ground circuit and a 5-volt reference signal circuit. As the temperature of the A/C evaporator decreases, the internal resistance of the evaporator temperature sensor decreases. The A/C-heater control uses the monitored voltage reading as an indication of evaporator temperature. The A/C-heater control is programmed to respond to this input by requesting the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) to cycle the A/C compressor clutch as necessary to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor is diagnosed using a scan tool. The evaporator temperature sensor cannot be adjusted or repaired and must be replaced if found inoperative or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Removal Evaporator Temperature Sensor / Switch: Service and Repair Removal REMOVAL NOTE: Illustration shown with instrument panel removed for clarity. 1. Disconnect and isolate the negative battery cable. 2. Remove the glove box from the instrument panel. 3. Disconnect the HVAC wire harness (1) from the evaporator temperature sensor (2) located on the top of the HVAC housing (3). 4. Remove the evaporator temperature sensor from the HVAC housing by pulling the sensor upward while tipping it forward. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Removal > Page 1224 Evaporator Temperature Sensor / Switch: Service and Repair Installation INSTALLATION NOTE: Illustration shown with instrument panel removed for clarity. 1. Install the evaporator temperature sensor (2) into the opening in the top of the HVAC housing (3). Make sure the sensor is fully engage to the housing. 2. Connect the HVAC wire harness (1) to the evaporator temperature sensor. 3. Install the glove box. 4. Reconnect the negative battery cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Component ID: 496 Component : TRANSDUCER-A/C PRESSURE Connector: Name : TRANSDUCER-A/C PRESSURE Color : BLACK # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 A/C PRESSURE GROUND C918 18BK/LB 2 A/C PRESSURE 5 VOLT SUPPLY C818 18LB/OR 3 A/C PRESSURE SIGNAL C18 18LB/BR 4-Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1228 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1229 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1230 Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1231 Connector: Name : TRANSDUCER-A/C PRESSURE Color : GRAY # of pins : 4 Qualifier : (6.7L/GAS) Pin Description Circuit 1 A/C PRESSURE GROUND C918 18BK/LB Pin Description Circuit 1 A/C PRESSURE GROUND C918 20BK/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1232 2 A/C PRESSURE 5 VOLT SUPPLY C818 18LB/OR 2 A/C PRESSURE 5 VOLT SUPPLY C818 20LB/OR 3 A/C PRESSURE SIGNAL C18 18LB/BR 3 A/C PRESSURE SIGNAL C18 20LB/BR 4-Component Location - 8 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1233 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1234 Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1235 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1236 Refrigerant Pressure Sensor / Switch: Diagrams Component ID: 496 Component : TRANSDUCER-A/C PRESSURE Connector: Name : TRANSDUCER-A/C PRESSURE Color : BLACK # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 A/C PRESSURE GROUND C918 18BK/LB 2 A/C PRESSURE 5 VOLT SUPPLY C818 18LB/OR 3 A/C PRESSURE SIGNAL C18 18LB/BR 4-Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1237 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1238 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1239 Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1240 Connector: Name : TRANSDUCER-A/C PRESSURE Color : GRAY # of pins : 4 Qualifier : (6.7L/GAS) Pin Description Circuit 1 A/C PRESSURE GROUND C918 18BK/LB Pin Description Circuit 1 A/C PRESSURE GROUND C918 20BK/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1241 2 A/C PRESSURE 5 VOLT SUPPLY C818 18LB/OR 2 A/C PRESSURE 5 VOLT SUPPLY C818 20LB/OR 3 A/C PRESSURE SIGNAL C18 18LB/BR 3 A/C PRESSURE SIGNAL C18 20LB/BR 4-Component Location - 8 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1242 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1243 Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1244 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Description Refrigerant Pressure Sensor / Switch: Description and Operation Description DESCRIPTION The A/C pressure transducer (1) is a switch that is installed on a fitting located on the A/C discharge line. An internally threaded fitting on the A/C pressure transducer connects it to the externally threaded Schrader-type fitting on the A/C discharge line. A rubber O-ring seals the connection between the A/C pressure transducer and the discharge line fitting. The A/C pressure transducer is connected to the vehicle electrical system by a molded plastic connector with three terminals. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Description > Page 1247 Refrigerant Pressure Sensor / Switch: Description and Operation Operation OPERATION The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the A/C discharge line and its internal resistance changes in response to the pressures it monitors. The powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) provides a five volt reference signal and a sensor ground to the A/C pressure transducer, then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure. The PCM/ECM is programmed to respond to this and other sensor inputs by controlling the operation of the A/C compressor clutch and the radiator cooling fan to help optimize A/C system performance and to protect the system components from damage. The PCM/ECM will disengage the A/C compressor clutch when high side pressure rises above 3172 kPa (460 psi) and re-engage the clutch when high side pressure drops below 1999 kPa (290 psi). The A/C pressure transducer will also disengage the A/C compressor clutch if the high side pressure drops below 193 kPa (28 psi) and will re-engage the clutch when the high side pressure rises above 234 kPa (34 psi). If the refrigerant pressure rises above 1655 kPa (240 psi), the PCM will actuate the cooling fan. The A/C pressure transducer signal to the PCM/ECM also prevents the A/C compressor clutch from engaging when ambient temperatures are below about 10° C (50° F) due to the pressure/temperature relationship of the refrigerant. A Schrader-type valve in the A/C discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the A/C system. The A/C pressure transducer is diagnosed using a scan tool. The A/C pressure transducer cannot be adjusted or repaired and must be replaced if found inoperative or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Removal Refrigerant Pressure Sensor / Switch: Service and Repair Removal REMOVAL NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer. NOTE: Typical A/C pressure transducer and refrigerant line shown. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector (1) from the A/C pressure transducer (2) located on the A/C discharge line (3). 3. Remove the A/C pressure transducer from the fitting on the A/C discharge line and remove and discard the O-ring seal. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Removal > Page 1250 Refrigerant Pressure Sensor / Switch: Service and Repair Installation INSTALLATION NOTE: Use only the specified O-ring as it is made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor. NOTE: Typical A/C pressure transducer and refrigerant line shown. 1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the discharge line fitting (3). 2. Install the A/C pressure transducer (2) onto the A/C discharge line. Tighten the A/C pressure transducer securely. 3. Connect the wire harness connector (1) to the A/C pressure transducer. 4. Reconnect the negative battery cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Description and Operation > Description Door Switch: Description and Operation Description DESCRIPTION This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if ineffective or damaged, the door latch unit must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Description and Operation > Description > Page 1256 Door Switch: Description and Operation Operation OPERATION The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper electronic door ajar switch status messages to other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. The door ajar switches as well as the hard wired inputs and outputs of the switches may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1261 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1262 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1263 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1264 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1265 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1266 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1267 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1268 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1269 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1270 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1271 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1272 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1273 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1274 Fuel Gauge Sender: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1275 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1276 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1277 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1278 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 1279 Fuel Gauge Sender: Description and Operation DESCRIPTION The fuel tank module is installed in the top of the fuel tank. The fuel tank module contains the following components: - An electric fuel transfer (lift) pump - Fuel reservoir - A separate in-tank fuel filter - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection - A special lockring to retain module to fuel tank - Fuel return line connection. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Removal Fuel Gauge Sender: Service and Repair Removal REMOVAL 1. Drain and remove fuel tank. 2. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose. 3. Position Special Tool 9340 (3) into notches on outside edge of lockring (5). 4. Install 1/2 inch drive breaker bar (1) to tool 9340 (3). 5. Rotate breaker bar counterclockwise to remove lockring. 6. Remove lockring. The module will spring up slightly when lockring is removed. 7. Remove module from fuel tank. Be careful not to bend float arm while removing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Removal > Page 1282 Fuel Gauge Sender: Service and Repair Installation INSTALLATION CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced. 1. Using a new seal (gasket), position fuel pump module into opening in fuel tank. 2. Position lockring (5) over top of fuel pump module. 3. Rotate module until embossed alignment arrow points to center alignment mark. This step must be performed to prevent float from contacting side of fuel tank. Also be sure fuel fitting on top of pump module is pointed to drivers side of vehicle. 4. Install Special Tool 9340 (3) to lockring. 5. Install 1/2 inch drive breaker (1) into Special Tool 9340 (3). 6. Tighten lockring (clockwise) until all seven notches have engaged. 7. Install fuel tank. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Component ID: 474 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : GRAY # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 1286 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 1287 Parking Brake Warning Switch: Diagrams Component ID: 474 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : GRAY # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 1288 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Description Parking Brake Warning Switch: Description and Operation Description DESCRIPTION The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Description > Page 1291 Parking Brake Warning Switch: Description and Operation Operation OPERATION The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Page 1292 Parking Brake Warning Switch: Testing and Inspection PARK BRAKE SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: If the brake indicator stays ON with the ignition switch in the ON position and the park brake released, or comes ON while driving, the brake system must be diagnosed and repaired prior to performing the following tests. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an ineffective park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to STEP 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OKAY 3. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to STEP 2. If not OK, replace the ineffective park brake switch. 4. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Removal Parking Brake Warning Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Removal > Page 1295 Parking Brake Warning Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Reach under the left end of the instrument panel to position the park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 Nm (24 in. lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. 5. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Sensor-Water In Fuel Water In Fuel Sensor: Locations Sensor-Water In Fuel Component ID: 433 Component : SENSOR-WATER IN FUEL Connector: Name : SENSOR-WATER IN FUEL Color : BLACK # of pins : 2 Qualifier : (5.9L) A WATER IN FUEL SENSOR GROUND K923 18BR/WT B WATER IN FUEL SENSOR SIGNAL G123 18VT/LG Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Sensor-Water In Fuel > Page 1300 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Sensor-Water In Fuel > Page 1301 Connector: Name : SENSOR-WATER IN FUEL Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Sensor-Water In Fuel > Page 1302 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Sensor-Water In Fuel > Page 1303 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Sensor-Water In Fuel > Page 1304 Water In Fuel Sensor: Locations Water - In - Fuel Sensor The WIF sensor (2) is located on the bottom of the fuel filter housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 1305 Water In Fuel Sensor: Diagrams Component ID: 433 Component : SENSOR-WATER IN FUEL Connector: Name : SENSOR-WATER IN FUEL Color : BLACK # of pins : 2 Qualifier : (5.9L) A WATER IN FUEL SENSOR GROUND K923 18BR/WT B WATER IN FUEL SENSOR SIGNAL G123 18VT/LG Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 1306 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 1307 Connector: Name : SENSOR-WATER IN FUEL Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 1308 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 1309 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Description and Operation > Description Water In Fuel Sensor: Description and Operation Description DESCRIPTION The Water-In-Fuel (WIF) sensor (2) is located on the bottom of the fuel filter/water separator canister (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Description and Operation > Description > Page 1312 Water In Fuel Sensor: Description and Operation Operation OPERATION The sensor sends an input to the Engine Control Module (ECM) when it senses water in the fuel filter/water separator. As the water level in the filter/separator increases, the resistance across the WIF sensor decreases. This decrease in resistance is sent as a signal to the ECM and compared to a high water standard value. Once the value reaches 30 to 40 kilohms, the ECM will activate the water-in-fuel warning lamp through CCD bus circuits. This all takes place when the ignition key is initially put in the ON position. The ECM continues to monitor the input while the engine is running. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Description and Operation > Page 1313 Water In Fuel Sensor: Service and Repair Water-In-Fuel (WIF) Sensor Replacement: The WIF sensor (2) is located on the bottom of the fuel filter housing. The WIF sensor is not a separately serviceable item. If diagnostics have led you to replace this sensor, then the whole fuel filter assembly (1) needs to be changed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Component ID: 458 Component : SWITCH-BACKUP LAMP Connector: Name : SWITCH-BACKUP LAMP Color : BLACK # of pins : 2 Qualifier : (3.7L M/T/4.7L M/T) Pin Description Circuit 1 GROUND Z965 20BK 2 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1318 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1319 Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1320 Connector: Name : SWITCH-BACKUP LAMP Color : BLACK # of pins : 2 Qualifier : (M/T 5.7L HD/DIESEL M/T) Pin Description Circuit 1 GROUND Z965 20BK 2 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1321 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1322 Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1323 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1324 Backup Lamp Switch: Diagrams Component ID: 458 Component : SWITCH-BACKUP LAMP Connector: Name : SWITCH-BACKUP LAMP Color : BLACK # of pins : 2 Qualifier : (3.7L M/T/4.7L M/T) Pin Description Circuit 1 GROUND Z965 20BK 2 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1325 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1326 Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1327 Connector: Name : SWITCH-BACKUP LAMP Color : BLACK # of pins : 2 Qualifier : (M/T 5.7L HD/DIESEL M/T) Pin Description Circuit 1 GROUND Z965 20BK 2 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1328 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1329 Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1330 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Description and Operation > Description Backup Lamp Switch: Description and Operation Description DESCRIPTION Vehicles equipped with a manual transmission have a normally open, spring-loaded plunger type backup lamp switch (2). Vehicles with an optional electronic automatic transmission have a Transmission Range Sensor (TRS) that is used to perform several functions, including that of the backup lamp switch. Refer to the service and diagnostic information for the automatic transmission type installed in the vehicle. The backup lamp switch is located in a threaded hole on the side of the manual transmission housing. The switch has a threaded body and a hex formation near the plunger end of the switch. An integral connector receptacle at the end of the switch opposite the plunger connects the switch to the vehicle electrical system through a take out and connector of the engine wire harness. When installed, only the switch connector and the hex formation are visible on the outside of the transmission housing. The backup lamp switch cannot be adjusted or repaired and, if ineffective or damaged, the entire switch unit must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Description and Operation > Description > Page 1333 Backup Lamp Switch: Description and Operation Operation OPERATION The backup lamp switch controls the flow of battery voltage to the backup lamp bulbs through an output on the backup lamp feed circuit. The switch plunger is mechanically actuated by the gearshift mechanism within the transmission, which will depress the switch plunger and close the switch contacts whenever the REVERSE gear has been selected. The switch receives battery voltage through a fuse in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run) circuit whenever the ignition switch is in the ON position. The backup lamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Description and Operation > Page 1334 Backup Lamp Switch: Testing and Inspection BACKUP LAMP SWITCH 1. Disconnect and isolate the battery negative cable. 2. Raise and support the vehicle. 3. Locate and disconnect the engine wire harness connector for the backup lamp switch. 4. Check for continuity between the two terminal pins in the backup lamp switch connector receptacle. a. With the gear selector lever in the REVERSE position, there should be continuity. b. With the gear selector lever in any position other than REVERSE, there should be no continuity. 5. If the switch fails either of these two continuity tests, replace the ineffective backup lamp switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Component ID: 488 Component : SWITCH-STOP LAMP Connector: Name : SWITCH-STOP LAMP Color : BLACK # of pins : 6 Pin Description Circuit 1 FUSED B(+) A103 18GY/RD 2 BRAKE LAMP SWITCH OUTPUT L50 18WT/TN 3 S/C BRAKE SWITCH OUTPUT V30 20VT/WT 4 BRAKE SWITCH NO. 2 SIGNAL V32 20VT/YL 5 GROUND Z429 20BK/OR 6 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT Component Location - 41 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 1338 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 1339 Brake Light Switch: Diagrams Component ID: 488 Component : SWITCH-STOP LAMP Connector: Name : SWITCH-STOP LAMP Color : BLACK # of pins : 6 Pin Description Circuit 1 FUSED B(+) A103 18GY/RD 2 BRAKE LAMP SWITCH OUTPUT L50 18WT/TN 3 S/C BRAKE SWITCH OUTPUT V30 20VT/WT 4 BRAKE SWITCH NO. 2 SIGNAL V32 20VT/YL 5 GROUND Z429 20BK/OR 6 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT Component Location - 41 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 1340 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Description Brake Light Switch: Description and Operation Description DESCRIPTION The brake lamp switch (2) is a three circuit, spring-loaded plunger actuated switch that is secured to the steering column support bracket under the instrument panel on the driver side of the vehicle. The molded plastic switch housing has an integral connector receptacle (1) containing six terminal pins and featuring a Connector Position Assurance (CPA) lock. The switch is connected to the vehicle electrical system through a dedicated take out of the instrument panel wire harness. The switch plunger (3) extends through a mounting collar (4) on one end of the switch housing. The plunger has a one time telescoping self-adjustment feature that is activated after the switch is installed by moving an adjustment release lever (5) on the opposite end of the switch housing clockwise, until it locks into a position that is horizontal and parallel to the connector receptacle. An installed brake lamp switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or removed from its mounting position for any reason, it must be replaced with a new unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Description > Page 1343 Brake Light Switch: Description and Operation Operation OPERATION The brake lamp switch controls three independent circuits. These circuits are described as follows: - Brake Lamp Switch Circuit - A normally open brake lamp switch circuit receives a battery voltage input, and supplies this battery voltage to the brake lamps and the Controller Antilock Brake (CAB) on a brake lamp switch output circuit only when the brake pedal is depressed (brake lamp switch plunger released). - Brake Lamp Switch Signal Circuit - A normally closed brake lamp switch signal circuit receives a direct path to ground, and supplies this ground input to the Powertrain Control Module (PCM) on a brake lamp switch sense circuit only when the brake pedal is released (brake lamp switch plunger is depressed). - Speed Control Circuit - A normally closed speed control circuit receives a battery voltage input from the Powertrain Control Module on a speed control supply circuit, and supplies this battery voltage to the speed control servo solenoids (dump, vacuum, and vent) on a speed control brake switch output circuit only when the speed control system is turned ON and the brake pedal is released (brake lamp switch plunger is depressed). The components of the self-adjusting brake switch plunger consist of a two-piece telescoping plunger, a split plunger locking collar, and a release wedge. The release lever has a shaft with a wedge that spreads the plunger locking collar to an open or released position. After the switch is installed and the brake pedal is released, the plunger telescopes to the correct adjustment position. When the release lever is moved to the release position, the wedge is disengaged from the locking collar causing the collar to apply a clamping pressure to the two plunger halves, fixing the plunger length. The brake lamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 1344 Brake Light Switch: Testing and Inspection BRAKE LAMP SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. CAUTION: Do not remove the brake lamp switch from the mounting bracket. The self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 2. Disconnect the wire harness connector from the brake lamp switch. 3. Using an ohmmeter, perform the continuity tests at the terminal pins (1) in the brake lamp switch connector receptacle as shown in the Brake Lamp Switch Tests table. 4. If the switch fails any of the continuity tests, replace the ineffective brake lamp switch as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Removal Brake Light Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Locate the brake lamp switch (2) near the support bracket on the lower steering column (1). 3. Disconnect the wire harness connector (3) from the brake lamp switch. 4. Rotate the brake lamp switch housing clockwise about 30 degrees to align the tabs on the switch locking collar with the keyed hole in the switch mounting bracket. 5. Pull the switch straight back from the keyed hole to remove it from the bracket. CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 6. Discard the removed brake lamp switch . Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Removal > Page 1347 Brake Light Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 1. Depress and hold the brake pedal in the depressed position. 2. Align the tabs on the brake lamp switch locking collar with the keyed hole in the switch mounting bracket on the lower steering column (1). 3. Insert the tabs on the brake lamp switch locking collar through the keyed hole in the switch mounting bracket until the switch housing (2) is firmly seated against the bracket. 4. Rotate the switch housing counterclockwise about 30 degrees to engage the tabs on the locking collar with the switch mounting bracket. CAUTION: Do not release or pull up on the brake pedal before the switch plunger adjustment has been completed. 5. Release the brake pedal, but do not pull it upward. 6. Rotate the plunger adjustment release lever (4) clockwise until it locks into place. The lever should be parallel to the brake lamp switch connector receptacle. This action will set the switch plunger length to a final adjustment position and cannot be undone. If not performed properly the first time, a new brake lamp switch must be installed. 7. Reconnect the wire harness connector (3) to the brake lamp switch. 8. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Combination Switch: Locations Component ID: 472 Component : SWITCH-MULTIFUNCTION Connector: Name : SWITCH-MULTIFUNCTION Color : BLACK # of pins : 4 Pin Description Circuit 1 WASH/BEAM SELECT SWITCH SIGNAL G194 20VT/LG 2 WIPER/TURN/BEAM SELECT SWITCH RETURN L900 20WT/YL 3 TURN LAMPS SWITCH SIGNAL L12 20WT/OR 4 INTERMITTENT WIPER SWITCH SIGNAL W52 20BR/YL Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 1351 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 1352 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 1353 Combination Switch: Diagrams Component ID: 472 Component : SWITCH-MULTIFUNCTION Connector: Name : SWITCH-MULTIFUNCTION Color : BLACK # of pins : 4 Pin Description Circuit 1 WASH/BEAM SELECT SWITCH SIGNAL G194 20VT/LG 2 WIPER/TURN/BEAM SELECT SWITCH RETURN L900 20WT/YL 3 TURN LAMPS SWITCH SIGNAL L12 20WT/OR 4 INTERMITTENT WIPER SWITCH SIGNAL W52 20BR/YL Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 1354 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 1355 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Description Combination Switch: Description and Operation Description DESCRIPTION The multi-function switch (3) is located on the steering column, just below the steering wheel. The only visible components of the multi-function switch are the control stalk (2) and control knob (1) that extend through the steering column shrouds on the left side of the column, and the hazard warning push button (4) that extends through the shroud on the top of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator (5) are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. Three integral locating posts on the switch housing, one on the top and two on the bottom, slide into channels in a receptacle on the left side of the multi-function switch mounting housing near the top of the steering column to ensure proper positioning of the switch. Then two screws secure the switch to the mounting housing. A single integral connector receptacle containing four terminal pins on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The multi-function switch provides the vehicle operator with a control interface for the following functions: - Hazard Warning Control - The multi-function switch hazard warning push button provides two detent positions (ON and OFF) to control the hazard warning lamps. Headlamp Beam Selection - The multi-function switch control stalk provides detent switching for selection of the headlamp HIGH or LOW beams. There is also an intermediate momentary position that allows the headlamp high beam circuits to be momentarily flashed to provide an optical horn feature (sometimes referred to as flash-to-pass) as an optical signalling device. - Turn Signal Control - The multi-function switch control stalk provides momentary non-detent (lane change) switching or detent switching with automatic cancellation for both the left and right turn signal lamps. - Washer Control - The multi-function switch control knob provides a momentary WASH position for washer system operation. - Wiper Control - The multi-function switch control knob provides two continuous wipe switch positions, LOW speed or HIGH speed; and an intermittent wipe mode with five delay interval positions. The multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch must be replaced as a unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Description > Page 1358 Combination Switch: Description and Operation Operation OPERATION The multi-function switch uses resistor multiplexing to control the many functions and features it provides using only three hard wired output circuits. The switch receives a clean ground from the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a multi-function switch return circuit. It then provides outputs to the EMIC on a wash/beam select switch signal circuit to control washer and headlamp beam selection, on an intermittent wiper switch signal circuit to control wipers, and on a turn lamps switch signal circuit to control turn signal and hazard warning functions. The multi-function switch operates as follows: - Hazard Warning Control - The hazard warning push button of the multi-function switch is depressed to activate the hazard warning system, and depressed again to turn the system OFF. When the push button is actuated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic hazard switch status messages to the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The TIPM then energizes and flashes or de-energizes both the left and right turn signal circuits to provide the visual hazard warning. - Headlamp Beam Selection - The control stalk of the multi-function switch is pulled towards the steering wheel past a detent to actuate the integral beam select switch circuitry, or to an intermediate, momentary position before the detent to actuate the optical horn feature. Each time the control stalk is actuated to a detent position, the opposite headlamp beam from what is currently selected will be energized. Each time the control stalk is actuated to the momentary position with the headlamps turned OFF, the headlamp high beams will be illuminated for as long as the control stalk is held in this position. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic beam select switch status messages to the TIPM over the CAN data bus. The TIPM energizes or de-energizes the selected LOW or HIGH beam circuits. - Turn Signal Control - The control stalk of the multi-function switch is moved upward to activate the RIGHT turn signal circuitry, and, downward to activate the LEFT turn signal circuitry. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, the cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the LEFT turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. When a turn signal is activated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic turn signal switch status messages to the TIPM over the CAN data bus. The TIPM energizes and flashes or de-energizes the selected left or right turn signal circuits. - Washer Control - The control knob on the end of the multi-function switch control stalk is depressed towards the steering column to momentarily activate the washer pump in the WASH mode. The washer pump will continue to operate in the washer mode until the control knob is released. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic washer switch status messages to the TIPM over the CAN data bus. The TIPM responds by energizing or de-energizing the washer pump in the washer mode. - Wiper Control - The control knob on the end of the multi-function switch control stalk is rotated to one of the continuous wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the wiper mode. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic wiper switch status messages to the TIPM over the CAN data bus. The TIPM responds by energizing or de-energizing the wiper motor. The TIPM is programmed to operate the wiper motor at the selected low or high continuous wipe speed, and to provide the selected electronically controlled speed-sensitive intermittent wipe or wipe-after-wash mode features. The multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Page 1359 Combination Switch: Testing and Inspection MULTI-FUNCTION SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Remove the multi-function switch from the switch mounting housing on the steering column. 2. Disconnect the wire harness connector from the back of the multi-function switch. 3. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the Multi-Function Switch Tests table. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Page 1360 4. If the switch fails any of the tests, replace the ineffective multi-function switch as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Removal Combination Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag from the steering wheel. 3. Disconnect the steering wheel wire harness connectors from the upper clockspring connector receptacles. CAUTION: Be certain that the screws that secure the steering wheel puller to the steering wheel are fully engaged in the steering wheel armature without passing through the steering wheel and damaging the clockspring. 4. Remove the steering wheel from the steering column. 5. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 6. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 7. Using hand pressure, press inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 8. Remove the upper shroud from the lower shroud and the steering column. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Removal > Page 1363 9. Remove the one center screw that secures the lower shroud to the steering column (4). 10. Remove the lower shroud from the steering column. 11. Disconnect the wire harness connector (2) from the back of the multi-function switch housing (1). 12. Remove the two screws (4) that secure the switch to the multi-function switch mounting housing (3). 13. Grasp the switch control stalk and pull it toward the left side of the vehicle to remove the switch from the mounting housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Removal > Page 1364 Combination Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Slide the multi-function switch (1) into the multi-function switch mounting housing (3) from the left side. Be certain that the alignment pins on the top and bottom of the switch are properly engaged in the channels of the mounting housing. 2. Install and tighten the two screws (4) that secure the switch to the mounting housing. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the back of the switch housing. 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Removal > Page 1365 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). NOTE: When reinstalling the steering wheel, be certain to index the yellow rubber booted engagement dowel on the upper surface of the clockspring rotor between the two fins cast into the lower surface of the steering wheel armature hub. 10. Reinstall the steering wheel onto the steering column. 11. Reconnect the steering wheel wire harness connectors to the upper clockspring connector receptacles. Be certain that the steering wheel wire harness is routed between the steering wheel back trim cover and the steering wheel armature. 12. Reinstall the driver airbag onto the steering wheel. 13. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Description and Operation > Description Door Switch: Description and Operation Description DESCRIPTION This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if ineffective or damaged, the door latch unit must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Description and Operation > Description > Page 1370 Door Switch: Description and Operation Operation OPERATION The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper electronic door ajar switch status messages to other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. The door ajar switches as well as the hard wired inputs and outputs of the switches may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair > Removal Glove Box Lamp Switch: Service and Repair Removal LAMP/SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Open the glove box door. 3. Reach through the window in the instrument panel (2) glove box opening behind the switch to access and depress the retaining latch on either side of the glove box lamp and switch unit (3). 4. While holding the retaining latch depressed, push the glove box lamp and switch unit out through the mounting hole in the face of the instrument panel. 5. Disconnect the wire harness connector (1) from the glove box lamp and switch. 6. Remove the lamp and switch unit from the instrument panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair > Removal > Page 1375 Glove Box Lamp Switch: Service and Repair Installation LAMP/SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the glove box lamp and switch unit (3) to the instrument panel (2) glove box opening. 2. Reconnect the wire harness connector (1) to the lamp and switch unit. 3. Feed the wire harness back through the switch mounting hole. 4. Align the lamp and switch unit with the mounting hole in the instrument panel. 5. Using hand pressure, push the lamp and switch unit firmly and evenly into the mounting hole until it is fully seated. 6. Close the glove box door. 7. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Component ID: 466 Component : SWITCH-HEADLAMP Connector: Name : SWITCH-HEADLAMP Color : BLACK # of pins : 10 Pin Description Circuit 1 HEADLAMP/FOG LAMP SWITCH SIGNAL L116 20WT/LG 2 PANEL LAMPS DIMMER SIGNAL E2 20OR/BR 3 HEADLAMP SWITCH RETURN L115 20WT/YL 4 HEADLAMP SWITCH DIMMER SIGNAL E19 20OR/BR 5 GROUND Z407 20BK/OR 6 CARGO LAMP SWITCH SIGNAL L914 20WT/LG 7-- 8-9-10 - Component Location - 44 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1379 Component Location - 50 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1380 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1381 Headlamp Switch: Diagrams Component ID: 466 Component : SWITCH-HEADLAMP Connector: Name : SWITCH-HEADLAMP Color : BLACK # of pins : 10 Pin Description Circuit 1 HEADLAMP/FOG LAMP SWITCH SIGNAL L116 20WT/LG 2 PANEL LAMPS DIMMER SIGNAL E2 20OR/BR 3 HEADLAMP SWITCH RETURN L115 20WT/YL 4 HEADLAMP SWITCH DIMMER SIGNAL E19 20OR/BR 5 GROUND Z407 20BK/OR 6 CARGO LAMP SWITCH SIGNAL L914 20WT/LG 7-- 8-9-10 - Component Location - 44 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1382 Component Location - 50 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1383 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Description Headlamp Switch: Description and Operation Description DESCRIPTION The headlamp switch (1) is located on the instrument panel, to the left of the steering column. Two different switches are used. The standard switch features a three-position rotary knob (4) for exterior lighting control, a thumbwheel (2) for panel lamps dimming and interior lighting control, and a momentary push button (3) for cargo lamp control. An optional switch has a momentary PUSH function added to the rotary knob for front fog lamp control. Each of these switches is constructed of molded plastic. The rotary knob is molded plastic and knurled around its circumference to ease operator control. The thumbwheel is also plastic and knurled. On vehicles with optional fog lamps the rotary knob also has the text PUSH and an International Control and Display Symbol icon for Front Fog Light applied to it. The cargo lamp push button is plastic with a smooth finish and the text CARGO applied to it. The switch face plate is also labeled with graphics and icons to clearly identify the many functions of the rotary knob and thumbwheel. Three screws secure the switch to the back of the cluster bezel through integral mounting flanges that are molded to each side of the switch housing. The back of the switch housing has an integral connector receptacle containing terminal pins that connect the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. A panel dimmer controlled incandescent bulb soldered to the circuit board within the switch provides back lighting for visibility at night, but is not serviceable. The headlamp switch cannot be repaired and, if ineffective or damaged, it must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Description > Page 1386 Headlamp Switch: Description and Operation Operation OPERATION The headlamp switch uses two resistor multiplexed outputs and one conventional output to control the many functions and features it provides. The switch receives a clean ground from the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a headlamp switch return circuit. It then provides outputs to the EMIC on a headlamp switch signal circuit to control exterior lighting functions, on a panel lamps dimmer signal circuit to control panel dimmer and interior lighting functions, and on a cargo lamp return circuit to control the cargo lamps. The switch illumination circuit receives a path to ground at all times through the left instrument panel ground circuit. The illumination level is controlled by a Pulse-Width Modulated (PWM) output received from the EMIC on a headlamp switch illumination control circuit. The EMIC controls this output based upon the dimmer signal select mux input from the headlamp switch. The headlamp switch operates as follows: - Cargo Lamps Control - The cargo lamp push button on the headlamp switch is depressed to activate or deactivate the cargo lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by providing the appropriate cargo lighting control outputs through its internal cargo lamp driver circuit. Front Fog Lamps Control - For vehicles so equipped, the rotary knob on the headlamp switch is depressed to activate or deactivate the optional front fog lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic fog lamp switch status messages to the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The TIPM responds by energizing or de-energizing the front fog lamps and by sending an electronic message back to the EMIC to control the front fog lamp indicator. - Exterior Lighting Control - The rotary knob on the headlamp switch is rotated to a detent position to activate or deactivate the exterior lighting. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic exterior lighting switch status messages to the TIPM over the CAN data bus. The TIPM responds by energizing or de-energizing the park lamp and the high or low beam headlamp circuits, and by sending an electronic message back to the EMIC to control the high beam indicator. The TIPM also remembers which headlamp beams were last selected with the multi-function switch, and energizes those beams by default the next time the headlamps are turned ON. - Interior Lighting Control - The thumbwheel on the headlamp switch is rotated to the dome DEFEAT, dome ON, PARADE mode, or one of the six panel dimmer detent positions to control the interior courtesy/dome and panel lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by providing the appropriate interior lighting control outputs through its internal courtesy lamp driver circuits, electronic dimming level messages to other modules over the CAN data bus, and the proper PWM outputs to control dimming levels through several panel dimmer illumination control driver circuits. The headlamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Page 1387 Headlamp Switch: Testing and Inspection HEADLAMP SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Remove the cluster bezel from the instrument panel. 2. Disconnect the wire harness connector from the back of the headlamp switch. 3. Using an ohmmeter, test the resistance or continuity between the terminals of the switch as shown in the Headlamp Switch Tests table. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Page 1388 4. If the switch fails any of the tests, replace the ineffective headlamp switch as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Removal Headlamp Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel (1) from the instrument panel. 3. Disconnect the wire harness connector (3) from the back of the headlamp switch (4). 4. Place the cluster bezel face down on a suitable work surface. Be certain to take the proper precautions to protect the face of the bezel from cosmetic damage. 5. Remove the three screws (2) that secure the headlamp switch to the back of the cluster bezel. 6. Remove the headlamp switch from the cluster bezel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Removal > Page 1391 Headlamp Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the headlamp switch (4) to the back of the cluster bezel (1). 2. Install and tighten the three screws (2) that secure the headlamp switch to the cluster bezel. Tighten the screws to 2 Nm (20 in. lbs.). 3. Position the cluster bezel close enough to the instrument panel to reconnect the wire harness connector (3) to the back of the headlamp switch. 4. Reinstall the cluster bezel onto the instrument panel. 5. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams Horn Switch: Diagrams Component ID: 470 Component : SWITCH-HORN Connector: Name : SWITCH-HORN Color : WHITE # of pins : 2 Pin Description Circuit 1 HORN SWITCH SENSE X3 20DG/VT 2-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 1395 Horn Switch: Description and Operation DESCRIPTION The horn switch is serviced as a unit with the driver airbag trim cover. The horn switch can not be serviced separately. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1401 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1402 Accelerator Pedal Position Sensor: Diagrams Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1403 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 1406 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) provides the Engine Control Module (ECM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 1409 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1413 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1414 Air Flow Meter/Sensor: Diagrams Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1415 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1416 Air Flow Meter/Sensor: Description and Operation OPERATION The Mass Airflow (MAF) sensor is a frequency based device. A constant voltage is applied to a heated wire on the sensor. This wire is positioned in the air cleaner air stream and is heated by the electrical current that the voltage produces. As air flows across it, it cools down. The heated wire or film is a positive temperature coefficient resistor. This means that its resistance drops when its temperature drops. The drop in resistance allows more current to flow through it in order to maintain the programmed temperature. This current is changed to a frequency which is sent to the Engine Control Module (ECM) and interpreted as air flow. Adjustments for air temperature and humidity are taken into consideration because they also affect the temperature of the heated wire or film. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL The Mass Airflow Sensor (5) is located on the air cleaner cover (8). 1. Disconnect electrical connector (6) at sensor. 2. Remove two mounting screws (4). 3. Remove sensor from air cleaner cover. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 1419 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (4). 4. Install electrical connector (6). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Description and Operation Barometric Pressure Sensor: Description and Operation OPERATION The Inlet Air Temperature/Pressure Sensor is a combination dual-function sensor. The sensor element extends into the intake air stream at the top of the air filter housing. Ambient air temperature as well as barometric pressure is monitored by this sensor. The Engine Control Module (ECM) monitors signals from this sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Service and Repair > Removal Barometric Pressure Sensor: Service and Repair Removal REMOVAL The Inlet Air Temperature/Pressure Sensor (3) is located on the air cleaner cover. 1. Disconnect electrical connector (7) at sensor. 2. Remove mounting screw (2). 3. Remove sensor from air cleaner cover. 4. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Service and Repair > Removal > Page 1425 Barometric Pressure Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor (3) into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (2). 4. Install electrical connector (7). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Component ID: 388 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 BATT TEMP SIGNAL K25 20DB/VT 2 SENSOR GROUND K900 20DB/DG Component Location - 32 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1429 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1430 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1431 Battery Temperature Sensor: Diagrams Component ID: 388 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 BATT TEMP SIGNAL K25 20DB/VT 2 SENSOR GROUND K900 20DB/DG Component Location - 32 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1432 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1433 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Description DESCRIPTION The Battery Temperature Sensor (BTS) is used only on the diesel engine. It is attached to the battery tray located under the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description > Page 1436 Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Operation OPERATION The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Removal REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4) . 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3) . 3. Disconnect sensor from engine wire harness electrical connector. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal > Page 1439 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Installation INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1443 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1444 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1445 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1446 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1447 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1448 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1449 Camshaft Position Sensor: Diagrams Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1450 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1451 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1452 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1453 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1454 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1455 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) is located below the fuel injection pump. It is bolted to the back of the timing gear cover. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 1458 Camshaft Position Sensor: Description and Operation Operation 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) contains a hall effect device. A rotating target wheel (tonewheel) for the CMP is located on the front timing gear. This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CMP. When the leading edge of the tonewheel notch passes the tip of the CMP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CMP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The CMP provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses the CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal Camshaft Position Sensor: Service and Repair Removal 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) on the diesel engine is located below the fuel injection pump (1). It is bolted to the back of the timing gear cover. 1. Disconnect electrical connector (5) at CMP sensor. 2. Remove sensor mounting bolt (6). 3. Carefully twist sensor from timing gear cover. 4. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 1461 Camshaft Position Sensor: Service and Repair Installation 5.9L/6.7L DIESEL The CMP (1) is located on the back of the timing gear cover. 1. Clean out machined hole in back of timing gear cover. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into timing gear cover with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to back of timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in.lbs.). 5. Connect electrical connector to sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Description Coolant Temperature Sensor/Switch (For Computer): Description and Operation Description DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Description > Page 1466 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Operation OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air-fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: - for engine coolant temperature gauge operation through CAN Bus communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid on/off times - Cooling fan control - Temperature gauge operation - A/C cutoff at high coolant temperatures - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Removal Coolant Temperature Sensor/Switch (For Computer): Service and Repair Removal 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL WARNING: Hot, pressurized coolant can cause injury by scalding. Cooling system must be partially drained before removing the coolant temperature sensor. 1. Partially drain the cooling system. ECT LOCATION - 5.9L DIESEL 2. Remove heat shield (if equipped). 3. Disconnect the electrical connector (2) from the ETC sensor (3). 4. Remove the ETC sensor from the cylinder head. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Removal > Page 1469 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Installation 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL 1. Install sensor (1 or 3) to engine. 2. Tighten sensor to 18 Nm (13 ft. lbs.) torque. ECT LOCATION - 5.9L DIESEL 3. Connect electrical connector (2) to ETC sensor (1 or 3). 4. Install heat shield (if equipped). 5. Replace any lost engine coolant. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1473 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1474 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1475 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1476 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1477 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1478 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1479 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1480 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1481 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1482 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1483 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1484 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1485 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1486 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1487 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1488 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1489 Crankshaft Position Sensor: Diagrams Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1490 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1491 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1492 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1493 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1494 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1495 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1496 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1497 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1498 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1499 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1500 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1501 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1502 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1503 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1504 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1505 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The Crankshaft Position Sensor (CKP) on the diesel engine is attached at the front / left side of the engine next to the engine harmonic balancer (crankshaft damper). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 1508 Crankshaft Position Sensor: Description and Operation Operation OPERATION The Crankshaft Position Sensor (CKP) (5) is the primary engine speed indicator for the engine after the engine is running. The CKP contains a hall effect device. A rotating, notched target wheel (tonewheel) (3) for the CKP is attached to the engine harmonic balancer (2). This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CKP. When the leading edge of the tonewheel notch passes the tip of the CKP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CKP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The Camshaft Position Sensor (CMP) also provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses this CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal Crankshaft Position Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle 2. Disconnect electrical connector (4) at CKP sensor. 3. Remove 1 sensor mounting bolt (3). 4. Remove CKP sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 1511 Crankshaft Position Sensor: Service and Repair Installation INSTALLATION 1. Position and install CKP sensor (5) to engine. 2. Install 1 sensor mounting bolt and tighten to 9 Nm (80 in. lbs.) torque. 3. Install electrical connector (4) to CKP sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations Crankcase Pressure Sensor: Locations Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 1515 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 1516 Crankcase Pressure Sensor: Diagrams Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 1517 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 1518 Crankcase Pressure Sensor: Description and Operation OPERATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). The CP sensor monitors crankcase pressure that builds up as the result of combustion gas blow-by. The Engine Control Module (ECM) uses data from the CP sensor to determine the condition of the crankcase breather (ventilation) filter. The ECM can also determine if a crankcase breather (ventilation) filter is present. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal Crankcase Pressure Sensor: Service and Repair Removal REMOVAL The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Remove mounting screw (6). 2. Disconnect electrical connector (7). 3. Remove sensor (5) from valve cover (4). 4. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal > Page 1521 Crankcase Pressure Sensor: Service and Repair Installation INSTALLATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Check condition of sensor O-ring. 2. Install sensor (5) into valve cover (4). 3. Install mounting screw (6). Tighten to 3 Nm (27 in. lbs.) torque. 4. Connect electrical connector (7). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1526 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1527 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1528 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1529 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1530 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1531 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1532 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1533 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1536 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1537 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1538 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1539 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1540 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1541 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1542 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1543 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 1546 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 1549 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1554 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1555 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1556 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1557 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1558 Component Location - 25 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1559 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1562 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1563 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1564 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1565 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1566 Component Location - 25 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1567 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation DESCRIPTION The fuel tank module is installed in the top of the fuel tank. The fuel tank module contains the following components: - An electric fuel transfer (lift) pump - Fuel reservoir - A separate in-tank fuel filter - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection - A special lockring to retain module to fuel tank - Fuel return line connection. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Removal Fuel Level Sensor: Service and Repair Removal REMOVAL 1. Drain and remove fuel tank. 2. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose. 3. Position Special Tool 9340 (3) into notches on outside edge of lockring (5). 4. Install 1/2 inch drive breaker bar (1) to tool 9340 (3). 5. Rotate breaker bar counterclockwise to remove lockring. 6. Remove lockring. The module will spring up slightly when lockring is removed. 7. Remove module from fuel tank. Be careful not to bend float arm while removing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Removal > Page 1573 Fuel Level Sensor: Service and Repair Installation INSTALLATION CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced. 1. Using a new seal (gasket), position fuel pump module into opening in fuel tank. 2. Position lockring (5) over top of fuel pump module. 3. Rotate module until embossed alignment arrow points to center alignment mark. This step must be performed to prevent float from contacting side of fuel tank. Also be sure fuel fitting on top of pump module is pointed to drivers side of vehicle. 4. Install Special Tool 9340 (3) to lockring. 5. Install 1/2 inch drive breaker (1) into Special Tool 9340 (3). 6. Tighten lockring (clockwise) until all seven notches have engaged. 7. Install fuel tank. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Locations High Idle Switch: Locations Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 1577 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 1578 High Idle Switch: Diagrams Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 1579 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations Intake Air Temperature Sensor: Component Locations Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1584 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1585 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1586 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1587 Component Location - 4 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1588 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1589 Cab/Chassis Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. Pick Up Models Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1590 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1591 Intake Air Temperature Sensor: Connector Locations Component ID: 406 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (6.7L DH) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1592 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1593 Component Location - 7 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1594 Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 IAT SIGNAL K21 20DB/LG 2 SENSOR GROUND K900 20DB/DG Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1595 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1596 Component Location - 7 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1597 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor Intake Air Temperature Sensor: Diagrams Intake Air Temperature Sensor Component ID: 406 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (6.7L DH) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1600 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1601 Component Location - 7 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1602 Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 IAT SIGNAL K21 20DB/LG 2 SENSOR GROUND K900 20DB/DG Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1603 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1604 Component Location - 7 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1605 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1606 Intake Air Temperature Sensor: Diagrams Sensor-Temperature/Pressure-MAP Component ID: 427 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A SENSOR GROUND K210 18DB/TN B INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG C 5 VOLT SUPPLY F855 18PK/YL D BOOST PRESSURE SENSOR SIGNAL K37 18LB Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1607 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 BOOST PRESSURE SENSOR SIGNAL K37 18BR 2 5 VOLT SUPPLY F855 18PK/YL 3 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 3 CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR K735 18BR/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1608 4 SENSOR GROUND K916 18BR/OR Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1609 Intake Air Temperature Sensor: Diagrams Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1610 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1611 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1612 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1613 Component Location - 4 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1614 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1615 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Sensor-Temperature/Pressure-Intake Intake Air Temperature Sensor: Description and Operation Sensor-Temperature/Pressure-Intake OPERATION The Inlet Air Temperature/Pressure Sensor is a combination dual-function sensor. The sensor element extends into the intake air stream at the top of the air filter housing. Ambient air temperature as well as barometric pressure is monitored by this sensor. The Engine Control Module (ECM) monitors signals from this sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Sensor-Temperature/Pressure-Intake > Page 1618 Intake Air Temperature Sensor: Description and Operation Sensor-Temperature/Pressure-MAP OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet Intake Air Temperature Sensor: Service and Repair Sensor-Temperature/Pressure-Inlet Removal REMOVAL The Inlet Air Temperature/Pressure Sensor (3) is located on the air cleaner cover. 1. Disconnect electrical connector (7) at sensor. 2. Remove mounting screw (2). 3. Remove sensor from air cleaner cover. 4. Check condition of sensor O-ring. Installation INSTALLATION 1. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 1621 2. Position sensor (3) into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (2). 4. Install electrical connector (7). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 1622 Intake Air Temperature Sensor: Service and Repair Sensor-Temperature/Pressure-MAP Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Pick Up Models REMOVAL-PICK UP MODELS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 1623 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 1624 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Description Knock Sensor: Description and Operation Description DESCRIPTION Two knock sensors are bolted into the cylinder block under the intake manifold 3.7L, 4.7L & 8.3L. Two knock sensors are also used with the 5.7L. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Description > Page 1629 Knock Sensor: Description and Operation Operation OPERATION Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure Manifold Pressure/Vacuum Sensor: Locations Sensor-Manifold Absolute Pressure Component ID: 411 Component : SENSOR-MANIFOLD ABSOLUTE PRESSURE Connector: Name : SENSOR-MANIFOLD ABSOLUTE PRESSURE Color : GRAY # of pins : 3 Qualifier : (NGC) Pin Description Circuit 1 MAP SIGNAL K1 20VT/BR 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 1634 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 1635 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 1636 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 1637 Manifold Pressure/Vacuum Sensor: Locations Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 1638 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 1639 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 1640 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 1641 Component Location - 4 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 1642 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 1643 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 1644 Manifold Pressure/Vacuum Sensor: Locations Sensor-Temperature/Pressure-MAP Pick Up Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). Cab/Chassis Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Manifold Absolute Pressure Component ID: 411 Component : SENSOR-MANIFOLD ABSOLUTE PRESSURE Connector: Name : SENSOR-MANIFOLD ABSOLUTE PRESSURE Color : GRAY # of pins : 3 Qualifier : (NGC) Pin Description Circuit 1 MAP SIGNAL K1 20VT/BR 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 1647 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 1648 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 1649 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 1650 Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 1651 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 1652 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 1653 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 1654 Component Location - 4 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 1655 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 1656 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 1657 Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Temperature/Pressure-MAP Component ID: 427 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A SENSOR GROUND K210 18DB/TN B INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG C 5 VOLT SUPPLY F855 18PK/YL D BOOST PRESSURE SENSOR SIGNAL K37 18LB Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 1658 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 BOOST PRESSURE SENSOR SIGNAL K37 18BR 2 5 VOLT SUPPLY F855 18PK/YL 3 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 3 CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR K735 18BR/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 1659 4 SENSOR GROUND K916 18BR/OR Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Sensor-MAP Manifold Pressure/Vacuum Sensor: Description and Operation Sensor-MAP DESCRIPTION A combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is used. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Sensor-MAP > Page 1662 Manifold Pressure/Vacuum Sensor: Description and Operation Sensor-Temperature/Pressure-MAP OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Removal-Pick Up Models REMOVAL-PICK UP MODELS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 1665 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 1666 Manifold Pressure/Vacuum Sensor: Service and Repair Installation Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 1667 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1672 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1673 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1674 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1675 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1676 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1677 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1678 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1679 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1680 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1681 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1682 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1683 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1684 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1685 Oil Pressure Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1686 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1687 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1688 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1689 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1698 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1699 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1700 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1701 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1702 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1703 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1704 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1710 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1711 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1712 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 08-035-08 > Nov > 08 > Engine Controls - Oxygen Sensor Testing Information Oxygen Sensor: All Technical Service Bulletins Engine Controls - Oxygen Sensor Testing Information NUMBER: 08-035-08 GROUP: Electrical DATE: November 21, 2008 SUBJECT: Proper Testing Tools For Oxygen Sensor Terminals OVERVIEW: This bulletin describes the use of proper test probes to test the Oxygen (02) Sensor connector terminals equipped with the new TP2 style of sensor. MODELS: 2007-2009 (DH) 2500 Pick Up 2007-2009 (D1) 3500 Pick Up NOTE: This bulletin applies to models equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: The new TP2 style 02 sensors have smaller terminals that may be damaged (spread) when using standard Digital Volt Ohm Meter (DVOM) test probes. The recommended tool for these testing procedures is the Miller Tool # 6801 (Fig. 1) Two (2) of these probes are required when performing circuit tests as described in DealerCONNECT. The tool was originally included as part of Miller Tool # 6807 and # 8197A. Each of these kits contained one (1) # 6801 terminal probe. Two (2) additional Miller test probes # 6801 will be delivered to affected Dodge dealers shortly. Two (2) new terminal probes (# 6801) will be included and shipped as kit # 10190. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1722 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1723 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1724 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1729 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1730 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1731 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1732 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1733 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1734 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1735 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 08-035-08 > Nov > 08 > Engine Controls - Oxygen Sensor Testing Information Oxygen Sensor: All Technical Service Bulletins Engine Controls - Oxygen Sensor Testing Information NUMBER: 08-035-08 GROUP: Electrical DATE: November 21, 2008 SUBJECT: Proper Testing Tools For Oxygen Sensor Terminals OVERVIEW: This bulletin describes the use of proper test probes to test the Oxygen (02) Sensor connector terminals equipped with the new TP2 style of sensor. MODELS: 2007-2009 (DH) 2500 Pick Up 2007-2009 (D1) 3500 Pick Up NOTE: This bulletin applies to models equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: The new TP2 style 02 sensors have smaller terminals that may be damaged (spread) when using standard Digital Volt Ohm Meter (DVOM) test probes. The recommended tool for these testing procedures is the Miller Tool # 6801 (Fig. 1) Two (2) of these probes are required when performing circuit tests as described in DealerCONNECT. The tool was originally included as part of Miller Tool # 6807 and # 8197A. Each of these kits contained one (1) # 6801 terminal probe. Two (2) additional Miller test probes # 6801 will be delivered to affected Dodge dealers shortly. Two (2) new terminal probes (# 6801) will be included and shipped as kit # 10190. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1745 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1746 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1747 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1757 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1758 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1759 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1760 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1761 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1762 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1763 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen Oxygen Sensor: Locations Sensor - Oxygen The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1766 Oxygen Sensor: Locations Sensor - Oxygen 1/1 Component ID: 416 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : BLACK # of pins : 4 Qualifier : (3.7L/5.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1767 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1768 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1769 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1770 Connector: Name : SENSOR-OXYGEN 1/1 Color : GRAY # of pins : 4 Qualifier : (4.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1771 Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1772 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1773 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1774 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1775 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1776 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1777 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1778 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1779 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1780 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1781 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1782 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1783 Oxygen Sensor: Locations Sensor - Oxygen 1/2 Component ID: 417 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 4 Qualifier : (3.7L/5.7L LD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1784 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1785 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1786 Connector: Name : SENSOR-OXYGEN 1/2 Color : GRAY # of pins : 4 Qualifier : (4.7L/5.7L HD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1787 Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1788 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1789 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1790 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1791 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1792 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1793 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1794 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 1795 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor Oxygen Sensor: Diagrams Module-O2 Sensor Component ID: 207 Component : MODULE-O2 SENSOR Connector: Name : MODULE-O2 SENSOR Color : # of pins : 16 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 3 DIAGNOSTIC PORT LOW DATA LINK D132 20WT 4 O2 1/2 SIGNAL K141 20DB/YL 5 02 1/2 PUMP CURRENT K734 20BR/DG 6 O2 1/1 SIGNAL K41 20DB/LB 7 02 1/1 PUMP CURRENT K89 20BR/LG 8 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 9 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 10 GROUND Z902 20BK 11 DIAGNOSTIC PORT HIGH DATA LINK D133 20WT/OR 12 O2 1/2 RETURN K904 20DB/DG 13 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 14 O2 1/1 RETURN K902 20BR/DG 15 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 16 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB Connector: Name : MODULE-O2 SENSOR Color : # of pins : 16 Qualifier : (6.7L DIESEL) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1798 Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 3 DIAGNOSTIC PORT LOW DATA LINK D132 20WT 4 O2 1/2 SIGNAL K141 20DB/YL 5 02 1/2 PUMP CURRENT K734 20BR/DG 6 O2 1/1 SIGNAL K41 20DB/LB 7 02 1/1 PUMP CURRENT K89 20BR/LG 8 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 9 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 10 GROUND Z902 20BK 11 DIAGNOSTIC PORT HIGH DATA LINK D133 20WT/OR 12 O2 1/2 RETURN K904 20DB/DG 13 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 14 O2 1/1 RETURN K902 20BR/DG 15 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 16 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1799 Oxygen Sensor: Diagrams Sensor-Oxygen 1/1 Component ID: 416 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : BLACK # of pins : 4 Qualifier : (3.7L/5.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1800 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1801 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1802 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1803 Connector: Name : SENSOR-OXYGEN 1/1 Color : GRAY # of pins : 4 Qualifier : (4.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1804 Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1805 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1806 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1807 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1808 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1809 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1810 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1811 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1812 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1813 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1814 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1815 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1816 Oxygen Sensor: Diagrams Sensor-Oxygen 1/2 Component ID: 417 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 4 Qualifier : (3.7L/5.7L LD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1817 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1818 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1819 Connector: Name : SENSOR-OXYGEN 1/2 Color : GRAY # of pins : 4 Qualifier : (4.7L/5.7L HD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1820 Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1821 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1822 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1823 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1824 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1825 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1826 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1827 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1828 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models Oxygen Sensor: Description and Operation Description - Pick Up Models DESCRIPTION - PICK UP MODELS The two oxygen (O2) sensors (1) and (2) are located at each end of the #2 catalyst. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models > Page 1831 Oxygen Sensor: Description and Operation Operation - Pick Up Models OPERATION - PICK UP MODELS Two different six-wire O2 sensors are used. These sensors are titled 1/1 upstream (1), and 1/2 downstream (2). A separate O2 Sensor Module (1) is also used. The engine aftertreatment system monitors the O2 content in the diesel engine exhaust. The ECM monitors the exhaust gases for oxygen content and varies the rich/lean fuel mixture of the intake air fuel mixture to adjust the system. This diagnostic monitors the status message broadcast by the O2 Sensor Module (1) for the upstream O2 sensor's internal heater circuit. The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the O2 Sensor Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models > Page 1832 Oxygen Sensor: Description and Operation Oxygen Sensor Module Description - Pick Up Models DESCRIPTION - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). Operation - Pick Up Models OPERATION - PICK UP MODELS Two different six-wire O2 sensors are used. These sensors are titled 1/1 upstream, and 1/2 downstream. A separate O2 Sensor Module (1) is also used. The engine aftertreatment system monitors the O2 content in the diesel engine exhaust. The ECM monitors the exhaust gases for oxygen content and varies the rich/lean fuel mixture of the intake air fuel mixture to adjust the system. This diagnostic monitors the status message broadcast by the O2 Sensor Module (1) for the upstream O2 sensor's internal heater circuit. The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the O2 Sensor Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module Oxygen Sensor: Service and Repair Oxygen Sensor Module Removal - Pick Up Models REMOVAL - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). 1. Raise and support vehicle. 2. Disconnect electrical connector (2) at module (1). 3. Remove four bolts (3). 4. Remove module from frame rail. Installation - Pick Up Models INSTALLATION - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). 1. Position module (1) to frame rail (4). 2. Install four bolts (3). 3. Tighten bolts (3) to 6 Nm (53 in. lbs.) torque. 4. Connect electrical connector (2) to module (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 1835 5. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 1836 Oxygen Sensor: Service and Repair Removal REMOVAL - PICK UP MODELS The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: The exhaust manifold, exhaust pipes and catalytic converters become very hot during engine operation. Allow engine to cool before removing oxygen sensor. 1. Raise and support vehicle. 2. Disconnect main wire connector from O2S sensor pigtail harness. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove O2S sensor with an oxygen sensor removal and installation tool. 4. Clean threads in catalytic convertor using appropriate tap. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 1837 Oxygen Sensor: Service and Repair Installation INSTALLATION - PICK UP MODELS The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. Threads of NEW oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. Be careful not to get anti-seize compound on sensor tip. 1. Install O2S sensor. Tighten to 41 Nm (30 ft. lbs.) torque. 2. Connect O2S sensor pigtail harness to main wire harness connector. 3. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Description Power Steering Pressure Switch: Description and Operation Description DESCRIPTION A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will only be used on HD vehicles with the 5.7L engines. There is no pressure switch used for the 3.7L, 4.7L, 5.9LDiesel engine or the 5.7L LD vehicle pump. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Description > Page 1842 Power Steering Pressure Switch: Description and Operation Operation OPERATION The switch is used on the 5.7L V-8 engines HD vehicles only. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal Pressure Feedback Exhaust Sensor: Service and Repair Removal REMOVAL 1. Disconnect exhaust gas pressure sensor electrical connector (1). 2. Using a 6 point deepwell socket, remove exhaust gas sensor (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal > Page 1847 Pressure Feedback Exhaust Sensor: Service and Repair Installation INSTALLATION 1. Using a 6 point deepwell socket, install exhaust gas pressure sensor. 2. Tighten sensor to 18 Nm (13 ft. lbs.). 3. Connect exhaust gas pressure sensor electrical connector (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 1852 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 1853 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 1854 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 1855 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 1856 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 1857 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 1858 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 1859 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 1860 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 1861 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 1862 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 1865 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 1866 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 1867 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 1868 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 1869 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 1870 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 1871 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 1872 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 1873 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 1874 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 1875 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 1878 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 1879 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 1880 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 1881 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 1882 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 1885 TRS REMOVAL/INSTALLATION 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 1886 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 1887 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 1888 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 1889 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations Turbocharger Speed Sensor: Locations Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations > Page 1893 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations > Page 1894 Turbocharger Speed Sensor: Diagrams Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations > Page 1895 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1900 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1901 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1902 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1903 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1904 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1905 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1906 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1907 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1908 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1909 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1910 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1911 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1912 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1913 Vehicle Speed Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1914 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1915 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1916 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1917 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1923 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1924 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1925 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1926 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1927 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1928 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1929 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1930 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1933 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1934 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1935 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1936 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1937 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1938 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1939 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1940 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 1943 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 1946 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations Crankcase Pressure Sensor: Locations Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 1950 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 1951 Crankcase Pressure Sensor: Diagrams Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 1952 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 1953 Crankcase Pressure Sensor: Description and Operation OPERATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). The CP sensor monitors crankcase pressure that builds up as the result of combustion gas blow-by. The Engine Control Module (ECM) uses data from the CP sensor to determine the condition of the crankcase breather (ventilation) filter. The ECM can also determine if a crankcase breather (ventilation) filter is present. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal Crankcase Pressure Sensor: Service and Repair Removal REMOVAL The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Remove mounting screw (6). 2. Disconnect electrical connector (7). 3. Remove sensor (5) from valve cover (4). 4. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal > Page 1956 Crankcase Pressure Sensor: Service and Repair Installation INSTALLATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Check condition of sensor O-ring. 2. Install sensor (5) into valve cover (4). 3. Install mounting screw (6). Tighten to 3 Nm (27 in. lbs.) torque. 4. Connect electrical connector (7). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Diagrams EGR Temperature Sensor: Diagrams Component ID: 394 Component : SENSOR-EGR TEMPERATURE Connector: Name : SENSOR-EGR TEMPERATURE Color : # of pins : 2 Qualifier : (6.7L DC) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 EGR TEMPERATURE SENSOR SIGNAL K935 18DB Connector: Name : SENSOR-EGR TEMPERATURE Color : # of pins : 2 Qualifier : (6.7L DH/D1) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 EGR TEMPERATURE SENSOR SIGNAL K935 18DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Description and Operation > Operation-Cab/Chassis Models EGR Temperature Sensor: Description and Operation Operation-Cab/Chassis Models OPERATION-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near the EGR valve. The EGR temperature sensor is a negative temperature coefficient thermistor used to measure the temperature of the EGR gas flow after it exits the EGR cooler. The ECM (Engine Control Module) supplies 5-volts to the EGR temperature signal circuit. To determine the temperature of the EGR gas flow, the ECM monitors the change in voltage caused by changes in the resistance of the sensor. The ECM uses the exhaust gas recirculation temperature value for the engine protection system, and also for engine emissions control. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Description and Operation > Operation-Cab/Chassis Models > Page 1962 EGR Temperature Sensor: Description and Operation Operation-Pick Up Models OPERATION-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). A temperature probe (1) is located at the end of the sensor assembly (3). The EGR temperature sensor is a negative temperature coefficient thermistor used to measure the temperature of the EGR gas flow after it exits the EGR cooler. The ECM (Engine Control Module) supplies 5-volts to the EGR temperature signal circuit. To determine the temperature of the EGR gas flow, the ECM monitors the change in voltage caused by changes in the resistance of the sensor. The ECM uses the exhaust gas recirculation temperature value for the engine protection system, and also for engine emissions control. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal EGR Temperature Sensor: Service and Repair Removal Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near EGR valve. 1. Disconnect electrical connector (2) at sensor. 2. Remove sensor (1) from EGR tube (6). Removal-Pick Up Models REMOVAL-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 1965 1. If equipped, remove four cover bolts (2) and remove EGR crossover tube cover (1). 2. If equipped, remove EGR valve cover (2). 3. A pigtail wiring harness connects sensor to engine wiring harness. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 1966 4. Unscrew nut (2) at intake manifold. 5. Disconnect sensor pigtail harness electrical connector from engine wiring harness and remove sensor assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 1967 EGR Temperature Sensor: Service and Repair Installation Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near the EGR valve. 1. Clean EGR crossover tube at sensor mounting point. 2. Check condition of the sensors metal gasket and replace if necessary. 3. Install sensor (1) to EGR tube (6). Tighten to 18 Nm (13 ft. lbs.). 4. Connect electrical connector (2) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 1968 1. A pigtail wiring harness (3) connects the sensor to the engine wiring harness. 2. Position sensor probe (1) into intake manifold. 3. Screw and tighten nut (2) into intake manifold. 4. Connect electrical connector (4) to engine wiring harness. 5. Install EGR valve cover (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 1969 6. Install EGR crossover tube cover (1) and four cover bolts (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Description and Operation Exhaust Pressure Differential Sensor: Description and Operation DESCRIPTION The Exhaust Differential Pressure Sensor is remotely mounted on the transmission housing. Two pressure tubes measure pressure before and after the Diesel Particulate Filter (DPF)/Diesel Oxidation Catalyst (DOC). The sensor is critical for fail-safe of regeneration strategy, because it interprets high pressure drops as possible high soot loads. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Differential Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect electrical connector. 3. Disconnect hoses at pressure differential pressure sensor. 4. Remove mounting bolt and differential pressure sensor. 5. Remove mounting bolts (1). 6. Remove pressure differential pressure tubing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal > Page 1975 Exhaust Pressure Differential Sensor: Service and Repair Installation INSTALLATION 1. Install differential pressure tubing, if removed. Tighten fittings to 30 Nm (22 ft. lbs.). 2. Position differential pressure sensor (1). 3. Install mounting nuts (5) and bolts. Tighten to 10 Nm (89 in. lbs.). 4. Install hose (2) to the rear DPF tubing. 5. Install hose (3) to the front DPF tubing. 6. Connect electrical connector (6). 7. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal Pressure Feedback Exhaust Sensor: Service and Repair Removal REMOVAL 1. Disconnect exhaust gas pressure sensor electrical connector (1). 2. Using a 6 point deepwell socket, remove exhaust gas sensor (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal > Page 1980 Pressure Feedback Exhaust Sensor: Service and Repair Installation INSTALLATION 1. Using a 6 point deepwell socket, install exhaust gas pressure sensor. 2. Tighten sensor to 18 Nm (13 ft. lbs.). 3. Connect exhaust gas pressure sensor electrical connector (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1985 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1986 Accelerator Pedal Position Sensor: Diagrams Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1987 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 1990 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) provides the Engine Control Module (ECM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 1993 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1997 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1998 Air Flow Meter/Sensor: Diagrams Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1999 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2000 Air Flow Meter/Sensor: Description and Operation OPERATION The Mass Airflow (MAF) sensor is a frequency based device. A constant voltage is applied to a heated wire on the sensor. This wire is positioned in the air cleaner air stream and is heated by the electrical current that the voltage produces. As air flows across it, it cools down. The heated wire or film is a positive temperature coefficient resistor. This means that its resistance drops when its temperature drops. The drop in resistance allows more current to flow through it in order to maintain the programmed temperature. This current is changed to a frequency which is sent to the Engine Control Module (ECM) and interpreted as air flow. Adjustments for air temperature and humidity are taken into consideration because they also affect the temperature of the heated wire or film. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL The Mass Airflow Sensor (5) is located on the air cleaner cover (8). 1. Disconnect electrical connector (6) at sensor. 2. Remove two mounting screws (4). 3. Remove sensor from air cleaner cover. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 2003 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (4). 4. Install electrical connector (6). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure Fuel Pressure Sensor/Switch: Locations Sensor-Fuel Rail Pressure Component ID: 404 Component : SENSOR-FUEL RAIL PRESSURE Connector: Name : SENSOR-FUEL RAIL PRESSURE Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL RAIL SENSOR RETURN K915 18BR/WT Pin Description Circuit 1 SENSOR GROUND K916 18BR/OR 2 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 3 5 VOLT SUPPLY F855 18PK/YL Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure > Page 2008 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure > Page 2009 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure > Page 2010 Fuel Pressure Sensor/Switch: Locations Sensor-Fuel Pressure The fuel pressure sensor (1) is mounted to the rear of the fuel rail (6). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 2011 Fuel Pressure Sensor/Switch: Diagrams Component ID: 404 Component : SENSOR-FUEL RAIL PRESSURE Connector: Name : SENSOR-FUEL RAIL PRESSURE Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL RAIL SENSOR RETURN K915 18BR/WT Pin Description Circuit 1 SENSOR GROUND K916 18BR/OR 2 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 3 5 VOLT SUPPLY F855 18PK/YL Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 2012 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 2013 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 2014 Fuel Pressure Sensor/Switch: Description and Operation OPERATION The fuel pressure sensor monitors actual high-pressure within the fuel rail. An output signal from this sensor (relating to fuel pressure) is sent to the Engine Control Module (ECM). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal Fuel Pressure Sensor/Switch: Service and Repair Removal REMOVAL The fuel pressure sensor (1) is mounted to the rear of the fuel rail (6). 1. Remove two bolts (3) and bracket (4) at rear of cylinder head. 2. Remove engine oil dipstick tube mounting bolts. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal > Page 2017 3. Disconnect electrical connector (2) at sensor. 4. Remove sensor (1) from fuel rail. 5. Inspect sensor sealing surface. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal > Page 2018 Fuel Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Inspect fuel pressure sensor sealing surface. 2. Lubricate sensor threads with clean diesel fuel. 3. Install sensor (1) into fuel rail. 4. To prevent leaks, sensor must be tightened to 70 Nm (52 ft. lbs.). 5. Connect electrical connector (2) to sensor. 6. Install rear engine lift bracket (4) and bolts (3). Tighten to 77 Nm (57 ft. lbs.). 7. Install engine oil dipstick tube mounting bolts. 8. Start engine and check for fuel leaks. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations High Idle Switch: Locations Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 2022 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 2023 High Idle Switch: Diagrams Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 2024 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Pick Up Models Turbo Boost Sensor: Locations Pick Up Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Pick Up Models > Page 2029 Turbo Boost Sensor: Locations Cab/Chassis Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Page 2030 Turbo Boost Sensor: Description and Operation OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP Turbo Boost Sensor: Service and Repair Sensor-Temperature/Pressure-MAP Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Removal-Pick Up Models REMOVAL-PICK UP MODELS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP > Page 2033 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP > Page 2034 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP > Page 2035 Turbo Boost Sensor: Service and Repair Sensor-Turbocharger Speed Removal REMOVAL 1. Disconnect negative battery cable. 2. Disconnect speed sensor electrical connector. 3. Remove turbocharger speed sensor mounting bolt (1). 4. Remove turbocharger speed sensor (2). Installation INSTALLATION 1. Install turbocharger speed sensor. 2. Install turbocharger speed sensor mounting bolt. 3. Tighten bolt to 10 Nm (89 in. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Speed Sensor > Component Information > Locations Turbocharger Speed Sensor: Locations Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Speed Sensor > Component Information > Locations > Page 2039 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Speed Sensor > Component Information > Locations > Page 2040 Turbocharger Speed Sensor: Diagrams Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Speed Sensor > Component Information > Locations > Page 2041 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2046 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2047 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2048 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2049 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2050 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2051 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2052 Camshaft Position Sensor: Diagrams Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2053 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2054 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2055 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2056 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2057 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2058 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) is located below the fuel injection pump. It is bolted to the back of the timing gear cover. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 2061 Camshaft Position Sensor: Description and Operation Operation 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) contains a hall effect device. A rotating target wheel (tonewheel) for the CMP is located on the front timing gear. This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CMP. When the leading edge of the tonewheel notch passes the tip of the CMP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CMP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The CMP provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses the CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal Camshaft Position Sensor: Service and Repair Removal 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) on the diesel engine is located below the fuel injection pump (1). It is bolted to the back of the timing gear cover. 1. Disconnect electrical connector (5) at CMP sensor. 2. Remove sensor mounting bolt (6). 3. Carefully twist sensor from timing gear cover. 4. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 2064 Camshaft Position Sensor: Service and Repair Installation 5.9L/6.7L DIESEL The CMP (1) is located on the back of the timing gear cover. 1. Clean out machined hole in back of timing gear cover. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into timing gear cover with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to back of timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in.lbs.). 5. Connect electrical connector to sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2068 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2069 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2070 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2071 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2072 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2073 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2074 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2075 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2076 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2077 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2078 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2079 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2080 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2081 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2082 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2083 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2084 Crankshaft Position Sensor: Diagrams Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2085 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2086 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2087 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2088 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2089 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2090 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2091 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2092 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2093 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2094 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2095 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2096 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2097 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2098 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2099 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2100 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The Crankshaft Position Sensor (CKP) on the diesel engine is attached at the front / left side of the engine next to the engine harmonic balancer (crankshaft damper). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 2103 Crankshaft Position Sensor: Description and Operation Operation OPERATION The Crankshaft Position Sensor (CKP) (5) is the primary engine speed indicator for the engine after the engine is running. The CKP contains a hall effect device. A rotating, notched target wheel (tonewheel) (3) for the CKP is attached to the engine harmonic balancer (2). This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CKP. When the leading edge of the tonewheel notch passes the tip of the CKP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CKP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The Camshaft Position Sensor (CMP) also provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses this CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal Crankshaft Position Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle 2. Disconnect electrical connector (4) at CKP sensor. 3. Remove 1 sensor mounting bolt (3). 4. Remove CKP sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 2106 Crankshaft Position Sensor: Service and Repair Installation INSTALLATION 1. Position and install CKP sensor (5) to engine. 2. Install 1 sensor mounting bolt and tighten to 9 Nm (80 in. lbs.) torque. 3. Install electrical connector (4) to CKP sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal Ignition Switch Lock Cylinder: Service and Repair Removal REMOVAL The ignition key must be in the key cylinder (1) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at the underside of the key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal > Page 2112 Ignition Switch Lock Cylinder: Service and Repair Installation INSTALLATION The ignition key must be in the key cylinder (3) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (3) with the ignition switch (1). 2. Push the key cylinder (3) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Description Knock Sensor: Description and Operation Description DESCRIPTION Two knock sensors are bolted into the cylinder block under the intake manifold 3.7L, 4.7L & 8.3L. Two knock sensors are also used with the 5.7L. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Description > Page 2117 Knock Sensor: Description and Operation Operation OPERATION Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations Air Bag Deactivation Switch: Locations Component ID: 475 Component : SWITCH-PASSENGER AIRBAG ON/OFF Connector: Name : SWITCH-PASSENGER AIRBAG ON/OFF Color : BLACK # of pins : 6 Pin Description Circuit 1 PASSENGER AIRBAG MUX SWITCH SENSE R106 20LG/LB 2 PASSENGER AIRBAG MUX SWITCH RETURN R104 20LB/LG 3 PASSENGER AIRBAG INDICATOR DRIVER G104 20VT/GY 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 5-6-Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 2122 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 2123 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 2124 Air Bag Deactivation Switch: Diagrams Component ID: 475 Component : SWITCH-PASSENGER AIRBAG ON/OFF Connector: Name : SWITCH-PASSENGER AIRBAG ON/OFF Color : BLACK # of pins : 6 Pin Description Circuit 1 PASSENGER AIRBAG MUX SWITCH SENSE R106 20LG/LB 2 PASSENGER AIRBAG MUX SWITCH RETURN R104 20LB/LG 3 PASSENGER AIRBAG INDICATOR DRIVER G104 20VT/GY 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 5-6-Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 2125 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 2126 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Description Air Bag Deactivation Switch: Description and Operation Description DESCRIPTION The passenger airbag on/off switch (1) is standard equipment on all standard cab versions of this vehicle equipped with the dual front airbag system. This switch is a two-position, resistor multiplexed switch with a single integral amber Light-Emitting Diode (LED), and a non-coded key cylinder-type actuator. The switch is located in the lower right corner of the instrument panel center bezel, near the center of the instrument panel. When the switch is in its installed position, the only components visible through the dedicated opening of the center bezel are the switch bezel (2) and lens, the nomenclature imprinted on the lens, and the key cylinder actuator (3). The OFF position nomenclature of the switch is illuminated and visible only when that switch position is selected. The ON position of the switch is neither visible or illuminated but can be determined by the orientation of the slot of the key cylinder actuator. The remainder of the switch is concealed behind the switch bezel and the instrument panel center bezel. The passenger airbag on/off switch housing is constructed of molded plastic and has three integral mounting tabs. These mounting tabs are used to secure the switch to the back of the molded plastic switch bezel with three small screws. The molded plastic switch bezel also has three integral mounting tabs that are used to secure the switch and bezel unit to the instrument panel center bezel with three additional screws. A molded plastic connector receptacle on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The molded plastic harness connector insulator is keyed and latched to ensure proper and secure switch electrical connections. The passenger airbag on/off switch cannot be adjusted or repaired and, if ineffective or damaged, the switch must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Description > Page 2129 Air Bag Deactivation Switch: Description and Operation Operation OPERATION The passenger airbag on/off switch allows the customer to turn the passenger airbag function ON or OFF to accommodate certain uses of the right front seating position where airbag protection may not be desired. See the owner's manual in the vehicle glove box for specific recommendations on when to enable or disable the passenger airbag. The OFF indicator of the switch will be illuminated whenever the switch is turned to the OFF position and the ignition switch is in the ON position. The ignition key is the only key or object that should ever be inserted into the key cylinder actuator of the switch. The on/off switch requires only a partial key insertion to fully depress a spring-loaded locking plunger. The spring-loaded locking plunger prevents the user from leaving the key in the switch. The key will be automatically ejected when force is not applied. To actuate the passenger airbag on/off switch, insert the ignition key into the switch key actuator far enough to fully depress the plunger, then rotate the actuator to the desired switch position. When the switch key actuator is rotated to its clockwise stop (the key actuator slot will be aligned with the OFF nomenclature), the OFF indicator is illuminated and the passenger airbag is disabled. When the switch is rotated to its counterclockwise stop (the key actuator slot will be in a vertical position) the OFF indicator will be extinguished and the passenger airbag is enabled. The OFF indicator and the enabling or disabling of the passenger airbag is controlled electronically by the Occupant Restraint Controller (ORC) based upon inputs it receives from the on/off switch. The passenger airbag on/off switch connects one of two internal resistors in series between the passenger airbag MUX switch sense and passenger airbag mux switch return circuits of the ORC. The ORC continually monitors the resistance in these circuits to determine the switch position that has been selected. When the switch is in the OFF position, the ORC provides a ground input to the OFF indicator through the passenger airbag indicator driver circuit, which energizes the Light-Emitting Diode (LED) that illuminates the indicator. The ORC will store a Diagnostic Trouble Code (DTC) for any fault it detects in the passenger airbag on/off switch or OFF indicator circuits, and will illuminate the airbag indicator in the instrument cluster if a fault is detected. The hard wired circuits between the passenger airbag on/off switch and the ORC may be diagnosed using conventional diagnostic tools and procedures. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the passenger airbag on/off switch or the electronic controls and communication between other modules and devices that provide some features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the passenger airbag on/off switch or the electronic controls and communication related to passenger airbag on/off switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Service and Repair > Removal Air Bag Deactivation Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: A passenger airbag on/off switch is used only on standard cab vehicles equipped with dual front airbags. Quad cab and mega cab vehicles have a cubby bin installed in the instrument panel center bezel in place of the on/off switch. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the center bezel (1) from the instrument panel. 3. From the back of the center bezel, remove the three screws (2) that secure the passenger airbag on/off switch and bezel unit (3) to the back of the center bezel. 4. Remove the passenger airbag on/off switch and bezel from the center bezel as a unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Service and Repair > Removal > Page 2132 Air Bag Deactivation Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: A passenger airbag on/off switch is used only on standard cab vehicles equipped with dual front airbags. Quad cab and mega cab vehicles have a cubby bin installed in the instrument panel center bezel in place of the on/off switch. 1. Position the passenger airbag on/off switch and bezel unit (3) to the back of the center bezel (1). 2. Install and tighten the three screws (2) that secure the passenger airbag on/off switch bezel to the back of the center bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Reinstall the center bezel onto the instrument panel. 4. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left Impact Sensor: Locations Sensor-Front Impact-Left Component ID: 402 Component : SENSOR-FRONT IMPACT-LEFT Connector: Name : SENSOR-FRONT IMPACT-LEFT Color : YELLOW # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 2 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 2137 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 2138 Impact Sensor: Locations Sensor-Side Impact-Left 1 Component ID: 423 Component : SENSOR-SIDE IMPACT-LEFT 1 Connector: Name : SENSOR-SIDE IMPACT-LEFT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 2 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 3-4-Component Location - 58 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 2139 Component Location - 63 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 2140 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 2141 Impact Sensor: Locations Sensor-Side Impact-Right 1 Component ID: 424 Component : SENSOR-SIDE IMPACT-RIGHT 1 Connector: Name : SENSOR-SIDE IMPACT-RIGHT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 2 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 3-4-Component Location - 61 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 2142 Component Location - 64 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 2143 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left Impact Sensor: Diagrams Sensor-Front Impact-Left Component ID: 402 Component : SENSOR-FRONT IMPACT-LEFT Connector: Name : SENSOR-FRONT IMPACT-LEFT Color : YELLOW # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 2 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 2146 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 2147 Impact Sensor: Diagrams Sensor-Side Impact-Left 1 Component ID: 423 Component : SENSOR-SIDE IMPACT-LEFT 1 Connector: Name : SENSOR-SIDE IMPACT-LEFT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 2 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 3-4-Component Location - 58 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 2148 Component Location - 63 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 2149 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 2150 Impact Sensor: Diagrams Sensor-Side Impact-Right 1 Component ID: 424 Component : SENSOR-SIDE IMPACT-RIGHT 1 Connector: Name : SENSOR-SIDE IMPACT-RIGHT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 2 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 3-4-Component Location - 61 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 2151 Component Location - 64 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 2152 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Description Impact Sensor: Description and Operation Description Front FRONT Two front impact sensors (1) are used on this vehicle, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each front impact sensor is secured with a screw to the back of the right or left end of the lower radiator crossmember within the engine compartment. The sensor housing has an integral connector receptacle (4), an integral anti-rotation pin (3), and an integral mounting hole (2) with a metal sleeve to provide crush protection. The right and left front impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The front impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. The front impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Side SIDE Two side impact sensors (1) are used on this vehicle when it is equipped with the optional side curtain airbags, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each side sensor is secured with a nut within the right or left B-pillar just above the front seat belt retractors and behind the lower B-pillar trim within the passenger compartment. The sensor housing has an integral connector receptacle (2), an integral mounting stud (3), and an integral anti-rotation pin. The right and left side impact sensors are identical in construction and calibration. A cavity in the center of the molded plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The side impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Description > Page 2155 Impact Sensor: Description and Operation Operation Front FRONT The front impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the front impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to front impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Side SIDE The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through left or right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the side impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to side impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal Impact Sensor: Service and Repair Removal Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front supplemental restraints. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front supplemental restraint deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the screw (4) that secures the right or left front impact sensor (3) to the back of the right or left end of the lower radiator crossmember (1). 3. Disconnect the headlamp and dash wire harness connector (2) from the sensor connector receptacle. 4. Remove the right or left front impact sensor from the engine compartment. Side - Mega Cab SIDE - MEGA CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side curtain airbags. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 2158 1. Adjust the front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the nut (3) that secures the stud of the side impact sensor (4) to the inner B-pillar (2). 4. Reach through the large hole above the retractor mounting hole in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 5. Pull the side impact sensor out through the large hole in the B-pillar far enough to access and disconnect the body wire harness connector (1) from the sensor connector receptacle. 6. Remove the side impact sensor from the B-pillar. Side - Quad Cab SIDE - QUAD CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side curtain airbags. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 2159 1. Adjust the front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the nut (3) that secures the stud of the side impact sensor (2) to the inner B-pillar (1). 4. Reach through the large hole above the retractor mounting hole in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 5. Pull the side impact sensor out through the large hole in the B-pillar far enough to access and disconnect the body wire harness connector (4) from the sensor connector receptacle. 6. Remove the side impact sensor from the B-pillar. Side - Standard Cab SIDE - STANDARD CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side curtain airbags. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. 1. Adjust the driver or passenger side front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the front outboard seat belt and retractor from the inside of the B-pillar. 4. Remove the nut (4) that secures the stud of the side impact sensor (1) to the inner B-pillar. 5. Reach through the retractor mounting hole (3) in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 6. Pull the side impact sensor out of the B-pillar far enough to access and disconnect the body wire harness connector (2) from the sensor connector receptacle. 7. Remove the sensor from the B-pillar. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 2160 Impact Sensor: Service and Repair Installation Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front supplemental restraints. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front supplemental restraint deployment. 1. Position the right or left front impact sensor (3) into the engine compartment. 2. Reconnect the headlamp and dash wire harness connector (2) to the sensor connector receptacle. 3. Carefully position the sensor onto the back of the right or left end of the lower radiator crossmember (1). Be certain that the anti-rotation pin on the back of the sensor is engaged in the clearance hole of the crossmember. 4. Install and tighten the screw (4) that secures the sensor to the back of the crossmember. Tighten the screw to 10 Nm (90 in. lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Side - Mega Cab SIDE - MEGA CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side curtain airbags. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 2161 1. Position the side impact sensor (4) to the large hole above the retractor mounting hole in the inner B-pillar (2). 2. Reconnect the body wire harness connector (1) to the sensor connector receptacle. 3. Reach through the large hole above the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (3) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 Nm (70 in. lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Side - Quad Cab SIDE - QUAD CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side curtain airbags. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. 1. Position the side impact sensor (2) to the large hole above the retractor mounting hole in the inner B-pillar (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 2162 2. Reconnect the body wire harness connector (4) to the sensor connector receptacle. 3. Reach through the large hole above the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (3) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 Nm (70 in. lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Side - Standard Cab SIDE - STANDARD CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side curtain airbags. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. 1. Position the side impact sensor (1) to the retractor mounting hole (3) in the inner B-pillar. 2. Reconnect the body wire harness connector (2) to the sensor connector receptacle. 3. Reach through the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (4) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 Nm (70 in. lbs.). 5. Reinstall the front outboard seat belt and retractor to the inside of the B-pillar. 6. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Component ID: 483 Component : SWITCH-SEAT BELT-DRIVER Connector: Name : SWITCH-SEAT BELT-DRIVER Color : # of pins : 2 Qualifier : (HD) Pin Description Circuit 1 GROUND Z951 18BK 2 SEAT BELT SWITCH SENSE G10 20VT/LG Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 2166 Connector: Name : SWITCH-SEAT BELT-DRIVER Color : LT. GRAY # of pins : 2 Qualifier : (LD) Pin Description Circuit 1 GROUND Z917 20BK 2 DRIVER SEAT BELT SWITCH SENSE R57 20LG/GY Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 2167 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 2168 Seat Belt Buckle Switch: Diagrams Component ID: 483 Component : SWITCH-SEAT BELT-DRIVER Connector: Name : SWITCH-SEAT BELT-DRIVER Color : # of pins : 2 Qualifier : (HD) Pin Description Circuit 1 GROUND Z951 18BK 2 SEAT BELT SWITCH SENSE G10 20VT/LG Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 2169 Connector: Name : SWITCH-SEAT BELT-DRIVER Color : LT. GRAY # of pins : 2 Qualifier : (LD) Pin Description Circuit 1 GROUND Z917 20BK 2 DRIVER SEAT BELT SWITCH SENSE R57 20LG/GY Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 2170 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Description Seat Belt Buckle Switch: Description and Operation Description DESCRIPTION All vehicles are equipped with a driver side seat belt switch that is a small, normally open, single pole, single throw, leaf contact, momentary switch. The driver side seat belt switch is integral to the buckle (1) of the driver side front seat belt buckle, which is located on a stamped steel stanchion secured by a screw (3) to the inboard side of the driver side front seat cushion frame. The seat belt switch is connected to the vehicle electrical system through a two-lead pigtail wire and connector (4) on the seat belt buckle-half, which is connected to a wire harness connector and take out of the seat wire harness routed beneath the driver side front seat cushion in the passenger compartment. The seat belt switch cannot be adjusted or repaired. If ineffective or damaged, the entire driver side front seat belt buckle-half unit must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Description > Page 2173 Seat Belt Buckle Switch: Description and Operation Operation OPERATION The driver side seat belt switch is designed to control a path to ground for the seat belt switch sense input of the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). When the driver side front seat belt tip-half is inserted into the seat belt buckle, the switch closes the path to ground; and, when the driver side front seat belt tip-half is removed from the seat belt buckle, the switch opens the ground path. The switch is actuated by the latch mechanism within the seat belt buckle. The seat belt switch is connected in series between ground and the seat belt switch sense input of the instrument cluster. The seat belt switch receives ground at all times through its pigtail wire connection to the seat wire harness from a take out of the body wire harness. An eyelet terminal connector on the body wire harness ground take out is secured beneath a ground screw on the left cowl side inner panel, beneath the instrument panel. The seat belt switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Description and Operation > Description Seat Position Sensor: Description and Operation Description DESCRIPTION The seat track position sensor (2) is a Hall Effect-type sensor used on some vehicles. This sensor consists of a Hall Effect Integrated Circuit (IC) chip encased in potting material within a cavity of the molded plastic sensor housing. The sensor housing has a mounting slot containing an integral latch feature (1) and slides and latches onto a stamped metal blade-type bracket located on the inboard side of the upper inboard seat adjuster track near the rear of the driver side front seat. A molded connector receptacle (3) integral to the sensor housing is connected to the vehicle electrical system through a connector and take out of the driver seat wire harness beneath the front seat cushion frame. The seat track position sensor cannot be adjusted or repaired and, if ineffective or damaged, the entire sensor must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Description and Operation > Description > Page 2178 Seat Position Sensor: Description and Operation Operation OPERATION The seat track position sensor is designed to provide a seat position data input to the Occupant Restraint Controller (ORC) indicating whether the driver side front seat is in a full forward or a not full forward position. The ORC uses this data as an additional logic input for use in determining the appropriate deployment force to be used when deploying the multistage driver side front airbag. The seat track position sensor receives a nominal five volt supply from the ORC. The sensor communicates the seat position by modulating the voltage returned to the ORC on a sensor data circuit. The ORC also monitors the condition of the sensor circuits and will store a Diagnostic Trouble Code (DTC) for any fault that is detected, and sends messages over the Controller Area Network (CAN) data bus to illuminate the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The hard wired circuits between the seat track position sensor and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the seat track position sensor or the electronic controls and communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the seat track position sensor or the electronic controls and communication related to seat track position sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Removal Seat Position Sensor: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Reach under the front seat cushion to access the seat track position sensor (2) on a bracket (1) located on the inboard side near the rear of the upper inboard driver seat track (4). 3. Using a small screwdriver, hold the latch feature (3) depressed while sliding the connector end of the sensor off of the bracket. 4. Disconnect the seat wire harness connector (5) from the sensor connector receptacle. 5. Remove the sensor from under the front seat. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Removal > Page 2181 Seat Position Sensor: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Reach under the driver side front seat cushion to reconnect the seat wire harness connector (5) to the seat track position sensor (2) connector receptacle. Be certain that the latch on the connector is fully engaged. 2. Align the open end of the sensor to the slide tab of the sensor bracket (1) located on the inboard side near the rear of the upper inboard driver seat track (4). 3. Push the sensor firmly onto the bracket until the latch feature (3) snaps into place with an audible click. 4. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations Seat Sensor/Switch: Locations Component ID: 422 Component : SENSOR-SEAT TRACK POSITION-DRIVER Connector: Name : SENSOR-SEAT TRACK POSITION-DRIVER Color : DK. GRAY # of pins : 2 Qualifier : (EXCEPT HEATED SEATS) Pin Description Circuit 1 DRIVER SEAT POSITION SENSOR DATA R261 20LB/TN 2 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/GY Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 2185 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 2186 Seat Sensor/Switch: Diagrams Component ID: 422 Component : SENSOR-SEAT TRACK POSITION-DRIVER Connector: Name : SENSOR-SEAT TRACK POSITION-DRIVER Color : DK. GRAY # of pins : 2 Qualifier : (EXCEPT HEATED SEATS) Pin Description Circuit 1 DRIVER SEAT POSITION SENSOR DATA R261 20LB/TN 2 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/GY Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 2187 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Component ID: 388 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 BATT TEMP SIGNAL K25 20DB/VT 2 SENSOR GROUND K900 20DB/DG Component Location - 32 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 2192 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 2193 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 2194 Battery Temperature Sensor: Diagrams Component ID: 388 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 BATT TEMP SIGNAL K25 20DB/VT 2 SENSOR GROUND K900 20DB/DG Component Location - 32 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 2195 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 2196 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Description DESCRIPTION The Battery Temperature Sensor (BTS) is used only on the diesel engine. It is attached to the battery tray located under the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description > Page 2199 Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Operation OPERATION The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Removal REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4) . 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3) . 3. Disconnect sensor from engine wire harness electrical connector. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal > Page 2202 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Installation INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal Ignition Switch Lock Cylinder: Service and Repair Removal REMOVAL The ignition key must be in the key cylinder (1) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at the underside of the key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal > Page 2208 Ignition Switch Lock Cylinder: Service and Repair Installation INSTALLATION The ignition key must be in the key cylinder (3) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (3) with the ignition switch (1). 2. Push the key cylinder (3) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Switch-Clutch Interlock Neutral Safety Switch: Locations Switch-Clutch Interlock Component ID: 459 Component : SWITCH-CLUTCH INTERLOCK Connector: Name : SWITCH-CLUTCH INTERLOCK Color : GREEN # of pins : 2 Qualifier : (M/T) Pin Description Circuit 1 TRS T41 SIGNAL (P/N) T41 20YL/DB 2 GROUND Z911 20BK Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Switch-Clutch Interlock > Page 2213 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Switch-Clutch Interlock > Page 2214 Neutral Safety Switch: Locations Switch-Clutch Interlock/Upstop Component ID: 460 Component : SWITCH-CLUTCH INTERLOCK/UPSTOP Connector: Name : SWITCH-CLUTCH INTERLOCK/UPSTOP Color : # of pins : 6 Qualifier : (6.7L) Pin Description Circuit 1-2-3 CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT T26 18DG/OR 4 GROUND Z993 18BK 5-6-- Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Switch-Clutch Interlock > Page 2215 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Switch-Clutch Interlock Neutral Safety Switch: Diagrams Switch-Clutch Interlock Component ID: 459 Component : SWITCH-CLUTCH INTERLOCK Connector: Name : SWITCH-CLUTCH INTERLOCK Color : GREEN # of pins : 2 Qualifier : (M/T) Pin Description Circuit 1 TRS T41 SIGNAL (P/N) T41 20YL/DB 2 GROUND Z911 20BK Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Switch-Clutch Interlock > Page 2218 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Switch-Clutch Interlock > Page 2219 Neutral Safety Switch: Diagrams Switch-Clutch Interlock/Upstop Component ID: 460 Component : SWITCH-CLUTCH INTERLOCK/UPSTOP Connector: Name : SWITCH-CLUTCH INTERLOCK/UPSTOP Color : # of pins : 6 Qualifier : (6.7L) Pin Description Circuit 1-2-3 CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT T26 18DG/OR 4 GROUND Z993 18BK 5-6-- Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Switch-Clutch Interlock > Page 2220 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Description Power Steering Pressure Switch: Description and Operation Description DESCRIPTION A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will only be used on HD vehicles with the 5.7L engines. There is no pressure switch used for the 3.7L, 4.7L, 5.9LDiesel engine or the 5.7L LD vehicle pump. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Description > Page 2227 Power Steering Pressure Switch: Description and Operation Operation OPERATION The switch is used on the 5.7L V-8 engines HD vehicles only. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set Steering Angle Sensor: Customer Interest ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set NUMBER: 08-044-06 GROUP: Electrical DATE: October 07, 2006 SUBJECT: DTC C1240 - Steering Angle Sensor Over Travel Performance OVERVIEW: This bulletin involves the diagnosis and possible replacement of the Steering Angle Sensor. MODELS: 2007 (DR) Ram Truck NOTE: This bulletin applies to vehicle equipped with the Electronic Stability Program (sales code BNB) and built prior to October 03, 2006 (MDH 1003XX). SYMPTOM/CONDITION: The customer may experience an illumination on the instrument cluster of the "ABS" (Anti-Lock Brake System) and/or the "ESP / BAS" (Electronic Stability Program / Brake Assist System) Warning Lights. Investigation may reveal the presence of Diagnostic Trouble Code (DTC) C1240 Steering Angle Sensor Over Travel Performance (SAS). DIAGNOSIS: 1. Perform the diagnostic test procedure for DTC C1240. This diagnostic procedure can be found on TechCONNECT: select the SERVICE INFO tab > 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 340/445E5P AWAL > DIAGNOSIS and TESTING > C1240 - Steering Angle Sensor Over Travel Performance (SAS). 2. If the diagnostic test procedure for DTC C1240 determines that the Steering Angle Sensor is at fault, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Before starting this procedure, be certain that the front wheels are in the straight-ahead position. 1. Replace the steering column clockspring. Refer to TechCONNECT for detailed service procedures: select the SERVICE INFO tab > 8 - ELECTRICAL > RESTRAINTS > CLOCKSPRING > REMOVAL and INSTALLATION. 2. Clear offsets by initializing the ABS ECU using StarSCAN. 3. Perform the ABS VERIFICATION TEST. This test can be found in: 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 3401445E5P AWAL > STANDARD PROCEDURE > ABS VERIFICATION TEST. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set > Page 2236 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set Steering Angle Sensor: All Technical Service Bulletins ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set NUMBER: 08-044-06 GROUP: Electrical DATE: October 07, 2006 SUBJECT: DTC C1240 - Steering Angle Sensor Over Travel Performance OVERVIEW: This bulletin involves the diagnosis and possible replacement of the Steering Angle Sensor. MODELS: 2007 (DR) Ram Truck NOTE: This bulletin applies to vehicle equipped with the Electronic Stability Program (sales code BNB) and built prior to October 03, 2006 (MDH 1003XX). SYMPTOM/CONDITION: The customer may experience an illumination on the instrument cluster of the "ABS" (Anti-Lock Brake System) and/or the "ESP / BAS" (Electronic Stability Program / Brake Assist System) Warning Lights. Investigation may reveal the presence of Diagnostic Trouble Code (DTC) C1240 Steering Angle Sensor Over Travel Performance (SAS). DIAGNOSIS: 1. Perform the diagnostic test procedure for DTC C1240. This diagnostic procedure can be found on TechCONNECT: select the SERVICE INFO tab > 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 340/445E5P AWAL > DIAGNOSIS and TESTING > C1240 - Steering Angle Sensor Over Travel Performance (SAS). 2. If the diagnostic test procedure for DTC C1240 determines that the Steering Angle Sensor is at fault, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Before starting this procedure, be certain that the front wheels are in the straight-ahead position. 1. Replace the steering column clockspring. Refer to TechCONNECT for detailed service procedures: select the SERVICE INFO tab > 8 - ELECTRICAL > RESTRAINTS > CLOCKSPRING > REMOVAL and INSTALLATION. 2. Clear offsets by initializing the ABS ECU using StarSCAN. 3. Perform the ABS VERIFICATION TEST. This test can be found in: 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 3401445E5P AWAL > STANDARD PROCEDURE > ABS VERIFICATION TEST. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set > Page 2242 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set Steering Angle Sensor: Customer Interest ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set NUMBER: 08-044-06 GROUP: Electrical DATE: October 07, 2006 SUBJECT: DTC C1240 - Steering Angle Sensor Over Travel Performance OVERVIEW: This bulletin involves the diagnosis and possible replacement of the Steering Angle Sensor. MODELS: 2007 (DR) Ram Truck NOTE: This bulletin applies to vehicle equipped with the Electronic Stability Program (sales code BNB) and built prior to October 03, 2006 (MDH 1003XX). SYMPTOM/CONDITION: The customer may experience an illumination on the instrument cluster of the "ABS" (Anti-Lock Brake System) and/or the "ESP / BAS" (Electronic Stability Program / Brake Assist System) Warning Lights. Investigation may reveal the presence of Diagnostic Trouble Code (DTC) C1240 Steering Angle Sensor Over Travel Performance (SAS). DIAGNOSIS: 1. Perform the diagnostic test procedure for DTC C1240. This diagnostic procedure can be found on TechCONNECT: select the SERVICE INFO tab > 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 340/445E5P AWAL > DIAGNOSIS and TESTING > C1240 - Steering Angle Sensor Over Travel Performance (SAS). 2. If the diagnostic test procedure for DTC C1240 determines that the Steering Angle Sensor is at fault, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Before starting this procedure, be certain that the front wheels are in the straight-ahead position. 1. Replace the steering column clockspring. Refer to TechCONNECT for detailed service procedures: select the SERVICE INFO tab > 8 - ELECTRICAL > RESTRAINTS > CLOCKSPRING > REMOVAL and INSTALLATION. 2. Clear offsets by initializing the ABS ECU using StarSCAN. 3. Perform the ABS VERIFICATION TEST. This test can be found in: 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 3401445E5P AWAL > STANDARD PROCEDURE > ABS VERIFICATION TEST. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set > Page 2252 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set Steering Angle Sensor: All Technical Service Bulletins ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set NUMBER: 08-044-06 GROUP: Electrical DATE: October 07, 2006 SUBJECT: DTC C1240 - Steering Angle Sensor Over Travel Performance OVERVIEW: This bulletin involves the diagnosis and possible replacement of the Steering Angle Sensor. MODELS: 2007 (DR) Ram Truck NOTE: This bulletin applies to vehicle equipped with the Electronic Stability Program (sales code BNB) and built prior to October 03, 2006 (MDH 1003XX). SYMPTOM/CONDITION: The customer may experience an illumination on the instrument cluster of the "ABS" (Anti-Lock Brake System) and/or the "ESP / BAS" (Electronic Stability Program / Brake Assist System) Warning Lights. Investigation may reveal the presence of Diagnostic Trouble Code (DTC) C1240 Steering Angle Sensor Over Travel Performance (SAS). DIAGNOSIS: 1. Perform the diagnostic test procedure for DTC C1240. This diagnostic procedure can be found on TechCONNECT: select the SERVICE INFO tab > 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 340/445E5P AWAL > DIAGNOSIS and TESTING > C1240 - Steering Angle Sensor Over Travel Performance (SAS). 2. If the diagnostic test procedure for DTC C1240 determines that the Steering Angle Sensor is at fault, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Before starting this procedure, be certain that the front wheels are in the straight-ahead position. 1. Replace the steering column clockspring. Refer to TechCONNECT for detailed service procedures: select the SERVICE INFO tab > 8 - ELECTRICAL > RESTRAINTS > CLOCKSPRING > REMOVAL and INSTALLATION. 2. Clear offsets by initializing the ABS ECU using StarSCAN. 3. Perform the ABS VERIFICATION TEST. This test can be found in: 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 3401445E5P AWAL > STANDARD PROCEDURE > ABS VERIFICATION TEST. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set > Page 2258 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Diagrams Suspension Mode Switch: Diagrams Component ID: 461 Component : SWITCH-DISCONNECTING STABILIZER BAR Connector: Name : SWITCH-DISCONNECTING STABILIZER BAR Color : BLACK # of pins : 12 Pin Description Circuit 1 LOCKER SWITCH SUPPLY T537 20YL/LG 2 LOCKER SWITCH SENSE T535 20YL/BR 3 STABILIZER BAR SWITCH SENSE T531 20YL/TN 4 SWITCH SUPPLY T536 20YL/WT 5 LOCKER OPEN ILLUMINATION SENSE T532 20YL/GY 6 LOCKER REAR ILLUMINATION SENSE T533 20YL/LB 7 LOCKER FR/RR ILLUMINATION SENSE T534 20YL 8 STABILIZER BAR DISENGAGE ILLUMINATION SENSE T530 20YL/DG 9 STABILIZER BAR ENGAGE ILLUMINATION SENSE T529 20YL/LG 10 - 11 PANEL LAMPS DRIVER E11 20OR/DB 12 GROUND Z952 20BK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Component ID: 410 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Description Circuit 1 SENSOR GROUND T160 20DG/WT Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 5 VOLT SUPPLY F856 20YL/PK 3 LINE PRESSURE SIGNAL T38 20YL/BR 4-- Component Location - 23 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 2267 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 2268 Fluid Pressure Sensor/Switch: Diagrams Component ID: 410 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Description Circuit 1 SENSOR GROUND T160 20DG/WT Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 5 VOLT SUPPLY F856 20YL/PK 3 LINE PRESSURE SIGNAL T38 20YL/BR 4-- Component Location - 23 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 2269 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description Fluid Pressure Sensor/Switch: Description and Operation Description DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, which is part of the pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the pump inlet. The system contains a Line Pressure Sensor, which is a direct input to the TCM. The line pressure sensor monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description > Page 2272 Fluid Pressure Sensor/Switch: Description and Operation Operation OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts, to ensure consistent shift quality. During all other operation, the desired line pressure value is adjusted based on torque level and other transmission requirements. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal Fluid Pressure Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal > Page 2275 Fluid Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Overdrive Switch: Locations Component ID: 490 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Description Circuit 123 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 4 GROUND Z71 20LB/BK 5 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 6 SENSOR GROUND T160 20DG/WT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 2279 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 2280 Overdrive Switch: Diagrams Component ID: 490 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Description Circuit 123 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 4 GROUND Z71 20LB/BK 5 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 6 SENSOR GROUND T160 20DG/WT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 2281 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 2282 Overdrive Switch: Testing and Inspection DIAGNOSIS AND TESTING - OVERDRIVE ELECTRICAL CONTROLS The tow/haul overdrive off switch, valve body solenoid, case connectors and related wiring can all be tested with a 12 volt test lamp or a volt/ohmmeter. Check continuity of each component when diagnosis indicates this is necessary. Switch and solenoid continuity should be checked whenever the transmission fails to shift into fourth gear range. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Switch: Service and Repair 42RLE Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2285 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2286 Overdrive Switch: Service and Repair 545RFE Automatic Transmission Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2287 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2288 Overdrive Switch: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2289 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2290 Overdrive Switch: Service and Repair AS68RC Automatic Transmission Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2291 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 2296 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 2297 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 2298 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 2299 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 2300 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 2301 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 2302 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 2303 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 2304 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 2305 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 2306 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 2309 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 2310 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 2311 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 2312 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 2313 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 2314 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 2315 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 2316 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 2317 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 2318 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 2319 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 2322 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 2323 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 2324 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 2325 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 2326 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 2329 TRS REMOVAL/INSTALLATION 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 2330 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 2331 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 2332 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 2333 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed Transmission Speed Sensor: Locations Sensor-Input Speed Component ID: 405 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2338 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2339 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2340 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2341 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2342 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2343 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2344 Transmission Speed Sensor: Locations Sensor-Output Speed Component ID: 415 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2345 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2346 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2347 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2348 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 18DG/BR 2 SPEED SENSOR GROUND T13 18DG/VT Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2349 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2350 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2351 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2352 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2353 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2354 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2355 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2356 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed Transmission Speed Sensor: Diagrams Sensor-Input Speed Component ID: 405 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2359 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2360 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2361 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2362 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2363 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2364 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2365 Transmission Speed Sensor: Diagrams Sensor-Output Speed Component ID: 415 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2366 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2367 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2368 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2369 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 18DG/BR 2 SPEED SENSOR GROUND T13 18DG/VT Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2370 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2371 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2372 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2373 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2374 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2375 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2376 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2377 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Speed Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The speed sensor (1) is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Operation OPERATION Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. Signals from this sensor are shared with the powertrain control module. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 2380 Transmission Speed Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 2381 Transmission Speed Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION INPUT AND OUTPUT SPEED SENSORS The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate DC square wave signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the "teeth" of the gear pass by the sensor coil, an DC square wave is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an DC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Transmission Speed Sensor: Service and Repair 68RFE Automatic Transmission Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the transmission case. Installation INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2384 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. Installation INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2385 Transmission Speed Sensor: Service and Repair AS68RC Automatic Transmission Output Speed Sensor OUTPUT SPEED SENSOR OUTPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor. 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. Input Speed Sensor INPUT SPEED SENSOR INPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2386 3. Remove the wiring connector from the input speed sensor. 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. Output Speed Sensor OUTPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. OUTPUT SPEED SENSOR 1. Lubricate the output speed sensor O-ring with MOPAR(R) AS68RC ATF. 2. Install the output speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the wiring connector onto the output speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC ATF as necessary. Input Speed Sensor INPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2387 INPUT SPEED SENSOR 1. Lubricate the output speed sensor O-ring with MOPAR(R) AS68RC ATF. 2. Install the input speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the electrical wiring connector onto the input speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC as necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Component ID: 431 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 TCC TEMPERATURE SIGNAL T819 20YL/VT 2 TEMPERATURE SENSOR GROUND T820 20YL/WT Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 2391 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 2392 Transmission Temperature Sensor/Switch: Diagrams Component ID: 431 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 TCC TEMPERATURE SIGNAL T819 20YL/VT 2 TEMPERATURE SENSOR GROUND T820 20YL/WT Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 2393 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection SWITCH-CLUTCH PEDAL POSITION 1. Disconnect switch 2-wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed - Continuity - Pedal Released - No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Description and Operation > Description Power Take-Off Switch: Description and Operation Description DESCRIPTION This Engine Control Module (ECM) input is used only on models equipped with aftermarket Power Take Off (PTO) units. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Description and Operation > Description > Page 2403 Power Take-Off Switch: Description and Operation Operation OPERATION This input is used only to tell the ECM that the aftermarket PTO (Power Take Off) unit has been engaged. The ECM will disable (temporarily shut down) certain OBD II diagnostic trouble codes when the PTO unit is engaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Component ID: 491 Component : SWITCH-TRANSFER CASE SELECTOR Connector: Name : SWITCH-TRANSFER CASE SELECTOR Color : BLACK # of pins : 10 Qualifier : (ETC) Pin Description Circuit 1 TRANSFER CASE POSITION SENSOR INPUT K77 20BR/WT 2-3 MODE SELECT K977 20BR/WT 4 PANEL LAMPS CONTROL E11 20OR/DB 5 GROUND Z905 20BK 6 NEUTRAL INDICATOR G95 20VT/BR 7 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 8-9-10 - Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 2408 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 2409 Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 2410 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 2411 Four Wheel Drive Selector Switch: Diagrams Component ID: 491 Component : SWITCH-TRANSFER CASE SELECTOR Connector: Name : SWITCH-TRANSFER CASE SELECTOR Color : BLACK # of pins : 10 Qualifier : (ETC) Pin Description Circuit 1 TRANSFER CASE POSITION SENSOR INPUT K77 20BR/WT 2-3 MODE SELECT K977 20BR/WT 4 PANEL LAMPS CONTROL E11 20OR/DB 5 GROUND Z905 20BK 6 NEUTRAL INDICATOR G95 20VT/BR 7 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 8-9-10 - Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 2412 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 2413 Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 2414 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case Four Wheel Drive Selector Switch: Description and Operation NV243 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 2417 For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere, is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 2418 Four Wheel Drive Selector Switch: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: - the AWD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 2419 The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 2420 Four Wheel Drive Selector Switch: Description and Operation NV246 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: - the AWD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 2421 For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 2422 Four Wheel Drive Selector Switch: Description and Operation NV273 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 2423 For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor Gear Sensor/Switch: Locations Assembly-Shift Motor/Mode Sensor Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2428 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2429 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2430 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2431 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2432 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2433 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2434 Gear Sensor/Switch: Locations Sensor-Transfer Case Position Component ID: 429 Component : SENSOR-TRANSFER CASE POSITION Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC) Pin Description Circuit 1 MODE SENSOR A D201 20WT/DG Pin Description Circuit 1 MODE SENSOR A D201 18WT/DG 2 GROUND Z955 20BK 2 GROUND Z955 18BK 2 GROUND Z901 20BK Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2435 Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2436 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor Gear Sensor/Switch: Diagrams Assembly-Shift Motor/Mode Sensor Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2439 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2440 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2441 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2442 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2443 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2444 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2445 Gear Sensor/Switch: Diagrams Sensor-Transfer Case Position Component ID: 429 Component : SENSOR-TRANSFER CASE POSITION Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC) Pin Description Circuit 1 MODE SENSOR A D201 20WT/DG Pin Description Circuit 1 MODE SENSOR A D201 18WT/DG 2 GROUND Z955 20BK 2 GROUND Z955 18BK 2 GROUND Z901 20BK Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2446 Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2447 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case Gear Sensor/Switch: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 2450 Mode Sensor Channel States Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 2451 Gear Sensor/Switch: Description and Operation NV246 Transfer Case Description DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The FCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Front Control Module (FCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to for the sensor codes returned to the FCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angle Vs. Transfer Case Position Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 2452 Mode Sensor Channel States Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 2453 Gear Sensor/Switch: Description and Operation NV271 Transfer Case Description DESCRIPTION The transfer case position sensor is an electronic device whose output can be interpreted to indicate the transfer case's current operating mode. The sensor consists of a five position, resistive multiplexed circuit which returns a specific resistance value to the Powertrain Control Module (PCM) for each transfer case operating mode. The sensor is located on the top of the transfer case, just left of the transfer case centerline and rides against the sector plate roostercomb. The PCM supplies 5VDC (+/- 0.5V) to the sensor and monitors the return voltage to determine the sector plate, and therefore the transfer case, position. Operation OPERATION Operating Mode Versus Resistance Position Sensor Linear Movement Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 2454 During normal vehicle operation, the Powertrain Control Module (PCM) monitors the transfer case position sensor return voltage to determine the operating mode of the transfer case. Refer to the Operating Mode Versus Resistance table for the correct resistance for each position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 2455 Gear Sensor/Switch: Description and Operation NV243 Transfer Case Description DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 2456 Mode Sensor Channel States Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 2457 Gear Sensor/Switch: Description and Operation NV273 Transfer Case Description DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 2458 Mode Sensor Channel States Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Removal Gear Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Disengage the transfer case position sensor connector from the position sensor. 3. Remove the position sensor from the transfer case. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Removal > Page 2461 Gear Sensor/Switch: Service and Repair Installation INSTALLATION 1. Inspect the O-ring seal on the transfer case position sensor. Replace the O-ring if necessary. 2. Install the transfer case position sensor into the transfer case. Torque the sensor to 27 Nm (20 ft.lbs.). 3. Engage the transfer case position sensor connector to the position sensor. 4. Lower vehicle. 5. Verify proper sensor operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front Speed Sensor: Locations Sensor-Prop Shaft Speed-Front Component ID: 420 Component : SENSOR-PROP SHAFT SPEED-FRONT Connector: Name : SENSOR-PROP SHAFT SPEED-FRONT Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR 2 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 2466 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 2467 Speed Sensor: Locations Sensor-Prop Shaft Speed-Rear Component ID: 421 Component : SENSOR-PROP SHAFT SPEED-REAR Connector: Name : SENSOR-PROP SHAFT SPEED-REAR Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 2 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 2468 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front Speed Sensor: Diagrams Sensor-Prop Shaft Speed-Front Component ID: 420 Component : SENSOR-PROP SHAFT SPEED-FRONT Connector: Name : SENSOR-PROP SHAFT SPEED-FRONT Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR 2 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 2471 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 2472 Speed Sensor: Diagrams Sensor-Prop Shaft Speed-Rear Component ID: 421 Component : SENSOR-PROP SHAFT SPEED-REAR Connector: Name : SENSOR-PROP SHAFT SPEED-REAR Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 2 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 2473 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Sensor-Output Shaft Speed-Front Speed Sensor: Service and Repair Sensor-Output Shaft Speed-Front Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connector from the front output shaft speed sensor (1). 3. Remove the front output shaft speed sensor from the transfer case. Installation INSTALLATION 1. Install the front output shaft speed sensor (1) into the transfer case. Tighten the speed sensor to 17 Nm (12.5 ft.lbs.). 2. Engage the wiring connector to the front output shaft speed sensor. 3. Lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Sensor-Output Shaft Speed-Front > Page 2476 Speed Sensor: Service and Repair Sensor-Output Shaft Speed-Rear Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connector from the rear output shaft speed sensor (1). 3. Remove the rear output shaft speed sensor from the transfer case. Installation INSTALLATION 1. Install the rear output shaft speed sensor (1) into the transfer case. Tighten the speed sensor to 17 Nm (12.5 ft.lbs.). 2. Engage the wiring connector to the rear output shaft speed sensor. 3. Lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Description Heated Glass Element Switch: Description and Operation Description DESCRIPTION The switch for the rear window defogger (EBL) system (1) is integrated into the A/C-heater control (2), which is located in the center of the instrument panel. When the rear window defogger switch is pressed to ON, a request signal is sent on the CAN-B Bus to the totally integrated power module (TIPM) to operate the EBL system. When the high side driver in the totally integrated power module (TIPM) is energized, current is directed to the rear defogger grid lines and to the heated side view mirrors. The grid lines heat the glass to help clear the surface of fog or frost. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Description > Page 2482 Heated Glass Element Switch: Description and Operation Operation OPERATION An amber indicator will illuminate when the rear window defogger switch is activated. When activated, the switch sends a request signal to the to the totally integrated power module (TIPM) to energize the internal EBL high side driver to provide battery current to the rear window defogger grid lines and to the heated side view mirrors. NOTE: The EBL system turns off automatically after 15 minutes of initial operation. Each following activation cycle of the EBL system will last 10 minutes. The EBL system will be automatically turned off after an initial programmed time interval of about 15 minutes, as long as the ignition switch is in RUN. After the initial time interval has expired, if the rear window defogger switch is pressed to ON again during the same ignition cycle, the EBL system will automatically turn off after about 10 minutes. The EBL system will automatically shut off if the ignition switch is turned to any position other than RUN, or it can be turned off manually by pressing the rear window defogger switch a second time. The rear window defogger switch is diagnosed using a scan tool. The rear window defogger switch and the rear window defogger indicator cannot be repaired and the A/C-heater control must be replaced if found inoperative or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite Power Window Switch: Locations Switch-Power Sliding Backlite Component ID: 476 Component : SWITCH-POWER SLIDING BACKLITE Connector: Name : SWITCH-POWER SLIDING BACKLITE Color : BLACK # of pins : 8 Qualifier : (QUAD CAB/EXCEPT BASE) Pin Description Circuit 1-2 GROUND Z794 12BK 3 GROUND Z975 12BK 4 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 12PK/YL 5 POWER BACKLITE OPEN (+) Q950 12OR/LG 6 PANEL LAMPS DRIVER P301 20LG/OR 7 GROUND Z976 20BK 8 POWER BACKLITE OPEN (-) Q951 12OR/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2487 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2488 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2489 Power Window Switch: Locations Switch-Power Window-Left Rear Component ID: 477 Component : SWITCH-POWER WINDOW-LEFT REAR Connector: Name : SWITCH-POWER WINDOW-LEFT REAR Color : BLUE # of pins : 6 Pin Description Circuit 1 DRIVER REAR WINDOW DRIVER (UP) Q111 14TN/YL Pin Description Circuit 1 DRIVER REAR WINDOW DRIVER (DOWN) Q211 14TN/LB 2 LEFT REAR WINDOW DRIVER (DOWN) Q611 14OR/GY 3-4 LEFT REAR WINDOW DRIVER (UP) Q411 14OR/WT 5 DRIVER REAR WINDOW DRIVER (DOWN) Q211 14TN/LB 5 DRIVER REAR WINDOW DRIVER (UP) Q111 14TN/YL 6 POWER WINDOW SWITCH FEED Q15 14OR/LB Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2490 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2491 Power Window Switch: Locations Switch-Power Window-Passenger Component ID: 478 Component : SWITCH-POWER WINDOW-PASSENGER Connector: Name : SWITCH-POWER WINDOW-PASSENGER Color : BLUE # of pins : 6 Pin Description Circuit 1 RIGHT FRONT WINDOW DRIVER (UP) Q12 12OR/BR 2 MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Q26 12OR/GY 3-4 MASTER WINDOW SWITCH RIGHT FRONT (UP) Q16 12OR/TN 5 RIGHT FRONT WINDOW DRIVER (DOWN) Q22 12OR/VT 6 POWER WINDOW SWITCH FEED Q15 12OR/LB Component Location - 56 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2492 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2493 Power Window Switch: Locations Switch-Power Window-Right Rear Component ID: 479 Component : SWITCH-POWER WINDOW-RIGHT REAR Connector: Name : SWITCH-POWER WINDOW-RIGHT REAR Color : BLUE # of pins : 6 Pin Description Circuit 1 PASSENGER REAR WINDOW DRIVER (UP) Q112 14TN/YL Pin Description Circuit 1 PASSENGER REAR WINDOW DRIVER (DOWN) Q212 14TN/LB 2 RIGHT REAR WINDOW DRIVER (DOWN) Q612 14OR/GY 3-4 RIGHT REAR WINDOW DRIVER (UP) Q412 14OR/WT 5 PASSENGER REAR WINDOW DRIVER (DOWN) Q212 14TN/LB 5 PASSENGER REAR WINDOW DRIVER (UP) Q112 14TN/YL 6 POWER WINDOW SWITCH FEED Q15 14TN/LG Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2494 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2495 Power Window Switch: Locations Switch-Window/Door Lock-Driver Component ID: 494 Component : SWITCH-WINDOW/DOOR LOCK-DRIVER Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C1 Color : BLUE # of pins : 12 Pin Description Circuit 1 RIGHT REAR WINDOW DRIVER (DOWN) Q612 14OR/DB 2 RIGHT REAR WINDOW DRIVER (UP) Q412 14OR/LB 3 MASTER WINDOW SWITCH RIGHT FRONT (UP) Q16 12OR/TN 4 LEFT REAR WINDOW DRIVER (UP) Q411 14OR/WT 5 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 6 MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Q26 12OR/GY 7 DRIVER DOOR LOCK SWITCH MUX G161 20VT/DG 8 GROUND Z939 12BK 9 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 12PK/YL 10 LEFT REAR WINDOW DRIVER (DOWN) Q611 14OR/GY 11 GROUND Z939 18BK 12 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2496 Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C2 Color : BLUE # of pins : 8 Pin Description Circuit 1 LEFT MIRROR UP DRIVER P71 20TN/DG 2 LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) P195 18LG/YL 3 FUSED B(+) A940 18RD 4 RIGHT MIRROR LEFT DRIVER P74 18TN/OR 5 GROUND Z939 18BK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2497 6 LEFT MIRROR LEFT DRIVER P75 20TN/LG 7 RIGHT MIRROR UP DRIVER P72 18TN/GY 8 POWER WINDOW SWITCH FEED Q15 12OR/LB Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite Power Window Switch: Diagrams Switch-Power Sliding Backlite Component ID: 476 Component : SWITCH-POWER SLIDING BACKLITE Connector: Name : SWITCH-POWER SLIDING BACKLITE Color : BLACK # of pins : 8 Qualifier : (QUAD CAB/EXCEPT BASE) Pin Description Circuit 1-2 GROUND Z794 12BK 3 GROUND Z975 12BK 4 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 12PK/YL 5 POWER BACKLITE OPEN (+) Q950 12OR/LG 6 PANEL LAMPS DRIVER P301 20LG/OR 7 GROUND Z976 20BK 8 POWER BACKLITE OPEN (-) Q951 12OR/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2500 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2501 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2502 Power Window Switch: Diagrams Switch-Power Window-Left Rear Component ID: 477 Component : SWITCH-POWER WINDOW-LEFT REAR Connector: Name : SWITCH-POWER WINDOW-LEFT REAR Color : BLUE # of pins : 6 Pin Description Circuit 1 DRIVER REAR WINDOW DRIVER (UP) Q111 14TN/YL Pin Description Circuit 1 DRIVER REAR WINDOW DRIVER (DOWN) Q211 14TN/LB 2 LEFT REAR WINDOW DRIVER (DOWN) Q611 14OR/GY 3-4 LEFT REAR WINDOW DRIVER (UP) Q411 14OR/WT 5 DRIVER REAR WINDOW DRIVER (DOWN) Q211 14TN/LB 5 DRIVER REAR WINDOW DRIVER (UP) Q111 14TN/YL 6 POWER WINDOW SWITCH FEED Q15 14OR/LB Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2503 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2504 Power Window Switch: Diagrams Switch-Power Window-Passenger Component ID: 478 Component : SWITCH-POWER WINDOW-PASSENGER Connector: Name : SWITCH-POWER WINDOW-PASSENGER Color : BLUE # of pins : 6 Pin Description Circuit 1 RIGHT FRONT WINDOW DRIVER (UP) Q12 12OR/BR 2 MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Q26 12OR/GY 3-4 MASTER WINDOW SWITCH RIGHT FRONT (UP) Q16 12OR/TN 5 RIGHT FRONT WINDOW DRIVER (DOWN) Q22 12OR/VT 6 POWER WINDOW SWITCH FEED Q15 12OR/LB Component Location - 56 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2505 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2506 Power Window Switch: Diagrams Switch-Power Window-Right Rear Component ID: 479 Component : SWITCH-POWER WINDOW-RIGHT REAR Connector: Name : SWITCH-POWER WINDOW-RIGHT REAR Color : BLUE # of pins : 6 Pin Description Circuit 1 PASSENGER REAR WINDOW DRIVER (UP) Q112 14TN/YL Pin Description Circuit 1 PASSENGER REAR WINDOW DRIVER (DOWN) Q212 14TN/LB 2 RIGHT REAR WINDOW DRIVER (DOWN) Q612 14OR/GY 3-4 RIGHT REAR WINDOW DRIVER (UP) Q412 14OR/WT 5 PASSENGER REAR WINDOW DRIVER (DOWN) Q212 14TN/LB 5 PASSENGER REAR WINDOW DRIVER (UP) Q112 14TN/YL 6 POWER WINDOW SWITCH FEED Q15 14TN/LG Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2507 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2508 Power Window Switch: Diagrams Switch-Window/Door Lock-Driver Component ID: 494 Component : SWITCH-WINDOW/DOOR LOCK-DRIVER Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C1 Color : BLUE # of pins : 12 Pin Description Circuit 1 RIGHT REAR WINDOW DRIVER (DOWN) Q612 14OR/DB 2 RIGHT REAR WINDOW DRIVER (UP) Q412 14OR/LB 3 MASTER WINDOW SWITCH RIGHT FRONT (UP) Q16 12OR/TN 4 LEFT REAR WINDOW DRIVER (UP) Q411 14OR/WT 5 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 6 MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Q26 12OR/GY 7 DRIVER DOOR LOCK SWITCH MUX G161 20VT/DG 8 GROUND Z939 12BK 9 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 12PK/YL 10 LEFT REAR WINDOW DRIVER (DOWN) Q611 14OR/GY 11 GROUND Z939 18BK 12 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2509 Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C2 Color : BLUE # of pins : 8 Pin Description Circuit 1 LEFT MIRROR UP DRIVER P71 20TN/DG 2 LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) P195 18LG/YL 3 FUSED B(+) A940 18RD 4 RIGHT MIRROR LEFT DRIVER P74 18TN/OR 5 GROUND Z939 18BK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2510 6 LEFT MIRROR LEFT DRIVER P75 20TN/LG 7 RIGHT MIRROR UP DRIVER P72 18TN/GY 8 POWER WINDOW SWITCH FEED Q15 12OR/LB Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Description Power Window Switch: Description and Operation Description DESCRIPTION A window/lock switch is used on all models equipped with power locks, power windows, and power mirrors. The window/lock switch houses the following switches: - Power Lock Switch - A two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Mirror Selector Switch - A three-position rocker switch selects the right or left power mirror for adjustment, or turns the power mirror system Off. - Power Mirror Adjustment Switches - Four momentary, arrowhead shaped, directional switches allow the driver to adjust the selected power mirror in the Up, Down, Right, or Left directions. - Power Window Lockout Switch - A two-way, latching, push-button switch allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches. - Power Window Switches - A two-way, momentary power window switch for the driver side front door. This switch also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, there are individual master switches for each passenger door power window. The window/lock switch also incorporates several green Light-Emitting Diodes (LEDs) that illuminate the power lock and power window switch paddles, and the power mirror switch directional buttons to improve switch visibility. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Description > Page 2513 Power Window Switch: Description and Operation Operation OPERATION The window/lock switch combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single unit. Power Lock Switch The power lock switch circuitry is connected in series between ground and the driver door switch mux input of the instrument cluster. Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the instrument cluster input, which allows the instrument cluster to sense the switch position. Based upon the power lock switch input, the instrument cluster controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door latches. The Light-Emitting Diode (LED) in the power lock switch is connected to battery current through the power window circuit breaker in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run-acc) circuit. The switch will be illuminated whenever the ignition switch is in the On or Accessory positions. Power Window Switches The power window switch circuitry is connected to battery current through a circuit breaker in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run-acc) circuit so that the power windows will operate whenever the ignition switch is in the On or Accessory positions. Each two-way, momentary master passenger power window switch provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The switch for the driver side front door power window is labeled "Auto" and includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the master switches. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Power Mirror Switches The power mirror switch circuitry is connected to battery current through a fuse in the TIPM on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one to select the left mirror, and a neutral Off position. After the right or left mirror is selected, one of four directional buttons is depressed to move the selected mirror Up, Down, Right or Left. The power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the power mirror switch is connected to battery current through the power window circuit breaker in the TIPM on a fused ignition switch output (run-acc) circuit so that the switch directional buttons will be illuminated whenever the ignition switch is in the On or Accessory positions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Window/Lock Switch Power Window Switch: Testing and Inspection Window/Lock Switch WINDOW/LOCK SWITCH The Light-Emitting Diode (LED) illumination lamps for all of the Driver Door Module (DDM) power window, power lock, and power mirror switches receive battery current through the power window circuit breaker in the Totally Integrated Power Module (TIPM). If all of the LED's are inoperative in the DDM, be certain to diagnose the power window system before replacing the switch unit. If only one LED in the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty DDM. Refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles. 2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position. If not OK, replace the faulty DDM as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Window/Lock Switch > Page 2516 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Window/Lock Switch > Page 2517 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Window/Lock Switch > Page 2518 Power Window Switch: Testing and Inspection Window Switch WINDOW SWITCH The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in both the power window and lock switch units and the power windows are inoperative. If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch units with the inoperative LED(s) is faulty and must be replaced. For complete circuit diagrams, refer to the appropriate wiring information. 1. Check the fuse in the Totally Integrated Power Module (TIPM) and the circuit breaker located near the park brake pedal. If OK, go to STEP 2. If not OK, replace the faulty fuse or circuit breaker. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the Totally Integrated Power Module (TIPM). If OK, turn the ignition switch to the Off position and go to STEP 3. If not OK, check circuit breaker and repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch unit from the door trim panel (passenger doors). The drivers door switch is included with the window/lock switch. Unplug the wire harness connector from the switch unit. 4. Test the power window switch continuity. See the Power Window Switch Continuity charts to determine if the continuity is correct in the Off, Up and Down switch positions . If OK, Refer to POWER WINDOWS TESTING. If not OK, replace the faulty switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Removal Power Window Switch: Service and Repair Removal REMOVAL FRONT PASSENGER 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel 3. Remove the switch from the trim panel bezel. REAR PASSENGER 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Gently pry switch from door trim panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Removal > Page 2521 Power Window Switch: Service and Repair Installation INSTALLATION FRONT PASSENGER 1. Insert switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. REAR PASSENGER 1. Install switch to door trim panel 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations Component ID: 492 Component : SWITCH-WASHER FLUID LEVEL Connector: Name : SWITCH-WASHER FLUID LEVEL Color : LT. GRAY # of pins : 2 Pin Description Circuit 1 WASHER FLUID SWITCH RETURN G932 20VT/TN 2 WASHER FLUID SWITCH SENSE W1 20BR/TN Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 2526 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 2527 Washer Fluid Level Switch: Diagrams Component ID: 492 Component : SWITCH-WASHER FLUID LEVEL Connector: Name : SWITCH-WASHER FLUID LEVEL Color : LT. GRAY # of pins : 2 Pin Description Circuit 1 WASHER FLUID SWITCH RETURN G932 20VT/TN 2 WASHER FLUID SWITCH SENSE W1 20BR/TN Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 2528 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Description Washer Fluid Level Switch: Description and Operation Description DESCRIPTION The washer fluid level switch (3) is a two-pin conductivity sensor with no moving parts mounted on the rearward facing side of the washer reservoir adjacent to the washer pump/motor unit in the engine compartment. Only the molded plastic switch mounting flange and the integral connector receptacle (4) are visible when the switch is installed in the reservoir. A short nipple formation (1) extends from the inner surface of the switch mounting flange, and a barb on the nipple is pressed through a rubber grommet seal installed in the mounting hole of the reservoir. Two over-molded pins or electrodes (2) extend from the back of the nipple formation. The washer fluid level switch cannot be adjusted or repaired. If ineffective or damaged, the switch must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Description > Page 2531 Washer Fluid Level Switch: Description and Operation Operation OPERATION The washer fluid level switch uses fluid conductivity to monitor the level of the washer fluid in the washer reservoir. Electricity is conducted between the two switch pins or electrodes only when they are immersed in the washer fluid, which closes the switch circuit. When the fluid level in the washer reservoir falls below the pins, electrical current cannot be conducted and the switch becomes an open circuit, which signals a low fluid condition. In order to prevent an electrical charge from accumulating in the electrical leads of the switch, the switch receives current that is pulsed from the Totally Integrated Power Module (TIPM) located in the engine compartment near the battery. The TIPM monitors the switch return signal and is programmed to respond to three consecutive open switch readings by sending an electronic washer fluid indicator lamp-ON message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) over the Controller Area Network (CAN) data bus. The EMIC responds to this message by illuminating the washer fluid indicator and by sounding an audible chime tone warning. The washer fluid level switch is connected to the vehicle electrical system through a dedicated take out and connector of the right (gasoline engines) or left (diesel engines) headlamp and dash wire harness. The switch is connected in series between a sensor return circuit and the washer fluid switch sense input to the TIPM. The washer fluid level switch and the hard wired circuits between the switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the washer fluid level switch or the electronic controls or communication between other modules and devices that provide some features of the wiper and washer systems. The most reliable, efficient, and accurate means to diagnose the washer fluid level switch or the electronic controls and communication related to washer fluid level switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Service and Repair > Removal Washer Fluid Level Switch: Service and Repair Removal DIESEL ENGINE NOTE: The washer fluid level switch can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the washer hose (4) from the barbed outlet nipple of the washer pump/motor unit (3) and allow the washer fluid to drain into a clean container for reuse. 3. Disconnect the left headlamp and dash wire harness (1) connector for the washer fluid level switch (5) from the switch connector receptacle. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal in the washer reservoir sump (2). Care must be taken not to damage the reservoir. 5. Remove the switch from the reservoir. 6. Remove the rubber grommet seal from the mounting hole in the washer reservoir and discard. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Service and Repair > Removal > Page 2534 Washer Fluid Level Switch: Service and Repair Installation DIESEL ENGINE 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole in the washer reservoir (2). Always use a new rubber grommet seal on the reservoir. 2. Insert the nipple formation of the switch (5) through the rubber grommet seal and in the reservoir. 3. Using hand pressure, press firmly and evenly on the switch mounting flange until the barbed nipple is fully seated in the rubber grommet seal in the reservoir. The flat edge of the switch mounting flange should be pointed upward. 4. Reconnect the left headlamp and dash wire harness (1) connector for the switch to the switch connector receptacle. 5. Reconnect the removed washer hose (4) to the barbed outlet nipple of the washer pump/motor unit (3). 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads Alignment: Customer Interest Steering - Front End Shimmy On Rough Roads NUMBER: 22-005-06 GROUP: Tire & Wheels DATE: October 07, 2006 SUBJECT: Front End Shimmy On 4x4 Vehicles When Traveling Over Rough Surfaces In The Road OVERVIEW: This bulletin involves verifying the condition of the vehicle front suspension and steering components, and adjusting the front tire pressure. MODELS: 2003 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to four wheel drive (4x4) 2500 and 3500 model vehicles. SYMPTOM/CONDITION: The customer may experience a self sustaining vibration (shimmy) felt in the front end of the vehicle after striking a bump or pothole. DIAGNOSIS: If the customer experiences the above condition perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on an alignment rack (drive-on lift). 2. Verify the road tires are correctly sized and the tire tread is not excessively worn. Replace any worn tire before proceeding. Any new or old replacement tire should be equal to the original tires that came with the vehicle when it was new. Tire wear is not covered by the vehicle warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads > Page 2544 3. Set the tire pressure for the FRONT TIRES to the following specification, regardless of the load being carried by the vehicle. 4. Set the tire pressure for the REAR TIRES as recommended for the vehicle configuration and load that is being carried at the time. 5. Verify that the steering damper is operating correctly. a. Unbolt the end of the damper at the axle end. b. Cycle the damper rod by hand. c. There should be resistance to motion in both directions of the damper rod. d. Replace the damper if no resistance is present. 6. Verify both outer tie rod ends dust covers are not worn. a. Attempt to rotate the dust cover by hand. b. If the dust cover on an outer tie rod end can be rotated, or is free and loose, then replace the tie rod (regardless of joint wear). 7. Inspect each outer tie rod end for internal wear. a. Maximum allowed wear (joint travel) for a tie rod end is 1.15 mm (0.045 in.). b. Install a dial indicator to the tie rod end (in-line with the vertical stud of the tie rod end). c. With a pry bar placed between the steering linkage and the axle tube, pry upwards while measuring the amount of joint travel (wear). d. Measure the amount of wear in the other outer tie rod end joint. e. If wear (joint travel) in either outer tie rod end is greater than 1.15 mm (0.045 in.), then replace the worn tie rod end. 8. Verify the torque on each outer tie rod end stud nut. The nut should be tightened to 122 Nm (90 ft. lbs.). 9. Make sure any worn outer tie rod ends have been replaced before proceeding further. 10. Verify all other steering linkage connections are tightened to their torque specifications. 11. Grease both outer tie rod ends (even if the outer tie rod is new). Apply sufficient grease to each tie rod end until grease is seen purging from the joint at the dust seal. 12. Align the vehicle front end. Adjust to specifications. 13. Road test the vehicle and verify the shimmy condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads > Page 2545 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads Alignment: All Technical Service Bulletins Steering - Front End Shimmy On Rough Roads NUMBER: 22-005-06 GROUP: Tire & Wheels DATE: October 07, 2006 SUBJECT: Front End Shimmy On 4x4 Vehicles When Traveling Over Rough Surfaces In The Road OVERVIEW: This bulletin involves verifying the condition of the vehicle front suspension and steering components, and adjusting the front tire pressure. MODELS: 2003 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to four wheel drive (4x4) 2500 and 3500 model vehicles. SYMPTOM/CONDITION: The customer may experience a self sustaining vibration (shimmy) felt in the front end of the vehicle after striking a bump or pothole. DIAGNOSIS: If the customer experiences the above condition perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on an alignment rack (drive-on lift). 2. Verify the road tires are correctly sized and the tire tread is not excessively worn. Replace any worn tire before proceeding. Any new or old replacement tire should be equal to the original tires that came with the vehicle when it was new. Tire wear is not covered by the vehicle warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads > Page 2551 3. Set the tire pressure for the FRONT TIRES to the following specification, regardless of the load being carried by the vehicle. 4. Set the tire pressure for the REAR TIRES as recommended for the vehicle configuration and load that is being carried at the time. 5. Verify that the steering damper is operating correctly. a. Unbolt the end of the damper at the axle end. b. Cycle the damper rod by hand. c. There should be resistance to motion in both directions of the damper rod. d. Replace the damper if no resistance is present. 6. Verify both outer tie rod ends dust covers are not worn. a. Attempt to rotate the dust cover by hand. b. If the dust cover on an outer tie rod end can be rotated, or is free and loose, then replace the tie rod (regardless of joint wear). 7. Inspect each outer tie rod end for internal wear. a. Maximum allowed wear (joint travel) for a tie rod end is 1.15 mm (0.045 in.). b. Install a dial indicator to the tie rod end (in-line with the vertical stud of the tie rod end). c. With a pry bar placed between the steering linkage and the axle tube, pry upwards while measuring the amount of joint travel (wear). d. Measure the amount of wear in the other outer tie rod end joint. e. If wear (joint travel) in either outer tie rod end is greater than 1.15 mm (0.045 in.), then replace the worn tie rod end. 8. Verify the torque on each outer tie rod end stud nut. The nut should be tightened to 122 Nm (90 ft. lbs.). 9. Make sure any worn outer tie rod ends have been replaced before proceeding further. 10. Verify all other steering linkage connections are tightened to their torque specifications. 11. Grease both outer tie rod ends (even if the outer tie rod is new). Apply sufficient grease to each tie rod end until grease is seen purging from the joint at the dust seal. 12. Align the vehicle front end. Adjust to specifications. 13. Road test the vehicle and verify the shimmy condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads > Page 2552 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 2553 Alignment: By Symptom Technical Service Bulletin # 22-005-06 Date: 061007 Steering - Front End Shimmy On Rough Roads NUMBER: 22-005-06 GROUP: Tire & Wheels DATE: October 07, 2006 SUBJECT: Front End Shimmy On 4x4 Vehicles When Traveling Over Rough Surfaces In The Road OVERVIEW: This bulletin involves verifying the condition of the vehicle front suspension and steering components, and adjusting the front tire pressure. MODELS: 2003 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to four wheel drive (4x4) 2500 and 3500 model vehicles. SYMPTOM/CONDITION: The customer may experience a self sustaining vibration (shimmy) felt in the front end of the vehicle after striking a bump or pothole. DIAGNOSIS: If the customer experiences the above condition perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on an alignment rack (drive-on lift). 2. Verify the road tires are correctly sized and the tire tread is not excessively worn. Replace any worn tire before proceeding. Any new or old replacement tire should be equal to the original tires that came with the vehicle when it was new. Tire wear is not covered by the vehicle warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 2554 3. Set the tire pressure for the FRONT TIRES to the following specification, regardless of the load being carried by the vehicle. 4. Set the tire pressure for the REAR TIRES as recommended for the vehicle configuration and load that is being carried at the time. 5. Verify that the steering damper is operating correctly. a. Unbolt the end of the damper at the axle end. b. Cycle the damper rod by hand. c. There should be resistance to motion in both directions of the damper rod. d. Replace the damper if no resistance is present. 6. Verify both outer tie rod ends dust covers are not worn. a. Attempt to rotate the dust cover by hand. b. If the dust cover on an outer tie rod end can be rotated, or is free and loose, then replace the tie rod (regardless of joint wear). 7. Inspect each outer tie rod end for internal wear. a. Maximum allowed wear (joint travel) for a tie rod end is 1.15 mm (0.045 in.). b. Install a dial indicator to the tie rod end (in-line with the vertical stud of the tie rod end). c. With a pry bar placed between the steering linkage and the axle tube, pry upwards while measuring the amount of joint travel (wear). d. Measure the amount of wear in the other outer tie rod end joint. e. If wear (joint travel) in either outer tie rod end is greater than 1.15 mm (0.045 in.), then replace the worn tie rod end. 8. Verify the torque on each outer tie rod end stud nut. The nut should be tightened to 122 Nm (90 ft. lbs.). 9. Make sure any worn outer tie rod ends have been replaced before proceeding further. 10. Verify all other steering linkage connections are tightened to their torque specifications. 11. Grease both outer tie rod ends (even if the outer tie rod is new). Apply sufficient grease to each tie rod end until grease is seen purging from the joint at the dust seal. 12. Align the vehicle front end. Adjust to specifications. 13. Road test the vehicle and verify the shimmy condition has been corrected. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 2555 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 22-005-06 Date: 061007 Steering - Front End Shimmy On Rough Roads NUMBER: 22-005-06 GROUP: Tire & Wheels DATE: October 07, 2006 SUBJECT: Front End Shimmy On 4x4 Vehicles When Traveling Over Rough Surfaces In The Road OVERVIEW: This bulletin involves verifying the condition of the vehicle front suspension and steering components, and adjusting the front tire pressure. MODELS: 2003 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to four wheel drive (4x4) 2500 and 3500 model vehicles. SYMPTOM/CONDITION: The customer may experience a self sustaining vibration (shimmy) felt in the front end of the vehicle after striking a bump or pothole. DIAGNOSIS: If the customer experiences the above condition perform the Repair Procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 2556 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on an alignment rack (drive-on lift). 2. Verify the road tires are correctly sized and the tire tread is not excessively worn. Replace any worn tire before proceeding. Any new or old replacement tire should be equal to the original tires that came with the vehicle when it was new. Tire wear is not covered by the vehicle warranty. 3. Set the tire pressure for the FRONT TIRES to the following specification, regardless of the load being carried by the vehicle. 4. Set the tire pressure for the REAR TIRES as recommended for the vehicle configuration and load that is being carried at the time. 5. Verify that the steering damper is operating correctly. a. Unbolt the end of the damper at the axle end. b. Cycle the damper rod by hand. c. There should be resistance to motion in both directions of the damper rod. d. Replace the damper if no resistance is present. 6. Verify both outer tie rod ends dust covers are not worn. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 2557 a. Attempt to rotate the dust cover by hand. b. If the dust cover on an outer tie rod end can be rotated, or is free and loose, then replace the tie rod (regardless of joint wear). 7. Inspect each outer tie rod end for internal wear. a. Maximum allowed wear (joint travel) for a tie rod end is 1.15 mm (0.045 in.). b. Install a dial indicator to the tie rod end (in-line with the vertical stud of the tie rod end). c. With a pry bar placed between the steering linkage and the axle tube, pry upwards while measuring the amount of joint travel (wear). d. Measure the amount of wear in the other outer tie rod end joint. e. If wear (joint travel) in either outer tie rod end is greater than 1.15 mm (0.045 in.), then replace the worn tie rod end. 8. Verify the torque on each outer tie rod end stud nut. The nut should be tightened to 122 Nm (90 ft. lbs.). 9. Make sure any worn outer tie rod ends have been replaced before proceeding further. 10. Verify all other steering linkage connections are tightened to their torque specifications. 11. Grease both outer tie rod ends (even if the outer tie rod is new). Apply sufficient grease to each tie rod end until grease is seen purging from the joint at the dust seal. 12. Align the vehicle front end. Adjust to specifications. 13. Road test the vehicle and verify the shimmy condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 22-005-06 Date: 061007 Steering - Front End Shimmy On Rough Roads NUMBER: 22-005-06 GROUP: Tire & Wheels Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 2558 DATE: October 07, 2006 SUBJECT: Front End Shimmy On 4x4 Vehicles When Traveling Over Rough Surfaces In The Road OVERVIEW: This bulletin involves verifying the condition of the vehicle front suspension and steering components, and adjusting the front tire pressure. MODELS: 2003 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to four wheel drive (4x4) 2500 and 3500 model vehicles. SYMPTOM/CONDITION: The customer may experience a self sustaining vibration (shimmy) felt in the front end of the vehicle after striking a bump or pothole. DIAGNOSIS: If the customer experiences the above condition perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on an alignment rack (drive-on lift). 2. Verify the road tires are correctly sized and the tire tread is not excessively worn. Replace any worn tire before proceeding. Any new or old replacement tire should be equal to the original tires that came with the vehicle when it was new. Tire wear is not covered by the vehicle warranty. 3. Set the tire pressure for the FRONT TIRES to the following specification, regardless of the load being carried by the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 2559 4. Set the tire pressure for the REAR TIRES as recommended for the vehicle configuration and load that is being carried at the time. 5. Verify that the steering damper is operating correctly. a. Unbolt the end of the damper at the axle end. b. Cycle the damper rod by hand. c. There should be resistance to motion in both directions of the damper rod. d. Replace the damper if no resistance is present. 6. Verify both outer tie rod ends dust covers are not worn. a. Attempt to rotate the dust cover by hand. b. If the dust cover on an outer tie rod end can be rotated, or is free and loose, then replace the tie rod (regardless of joint wear). 7. Inspect each outer tie rod end for internal wear. a. Maximum allowed wear (joint travel) for a tie rod end is 1.15 mm (0.045 in.). b. Install a dial indicator to the tie rod end (in-line with the vertical stud of the tie rod end). c. With a pry bar placed between the steering linkage and the axle tube, pry upwards while measuring the amount of joint travel (wear). d. Measure the amount of wear in the other outer tie rod end joint. e. If wear (joint travel) in either outer tie rod end is greater than 1.15 mm (0.045 in.), then replace the worn tie rod end. 8. Verify the torque on each outer tie rod end stud nut. The nut should be tightened to 122 Nm (90 ft. lbs.). 9. Make sure any worn outer tie rod ends have been replaced before proceeding further. 10. Verify all other steering linkage connections are tightened to their torque specifications. 11. Grease both outer tie rod ends (even if the outer tie rod is new). Apply sufficient grease to each tie rod end until grease is seen purging from the joint at the dust seal. 12. Align the vehicle front end. Adjust to specifications. 13. Road test the vehicle and verify the shimmy condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 2560 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 22-005-06 Date: 061007 Steering - Front End Shimmy On Rough Roads NUMBER: 22-005-06 GROUP: Tire & Wheels DATE: October 07, 2006 SUBJECT: Front End Shimmy On 4x4 Vehicles When Traveling Over Rough Surfaces In The Road OVERVIEW: This bulletin involves verifying the condition of the vehicle front suspension and steering components, and adjusting the front tire pressure. MODELS: 2003 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to four wheel drive (4x4) 2500 and 3500 model vehicles. SYMPTOM/CONDITION: The customer may experience a self sustaining vibration (shimmy) felt in the front end of the vehicle after striking a bump or pothole. DIAGNOSIS: If the customer experiences the above condition perform the Repair Procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 2561 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on an alignment rack (drive-on lift). 2. Verify the road tires are correctly sized and the tire tread is not excessively worn. Replace any worn tire before proceeding. Any new or old replacement tire should be equal to the original tires that came with the vehicle when it was new. Tire wear is not covered by the vehicle warranty. 3. Set the tire pressure for the FRONT TIRES to the following specification, regardless of the load being carried by the vehicle. 4. Set the tire pressure for the REAR TIRES as recommended for the vehicle configuration and load that is being carried at the time. 5. Verify that the steering damper is operating correctly. a. Unbolt the end of the damper at the axle end. b. Cycle the damper rod by hand. c. There should be resistance to motion in both directions of the damper rod. d. Replace the damper if no resistance is present. 6. Verify both outer tie rod ends dust covers are not worn. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 2562 a. Attempt to rotate the dust cover by hand. b. If the dust cover on an outer tie rod end can be rotated, or is free and loose, then replace the tie rod (regardless of joint wear). 7. Inspect each outer tie rod end for internal wear. a. Maximum allowed wear (joint travel) for a tie rod end is 1.15 mm (0.045 in.). b. Install a dial indicator to the tie rod end (in-line with the vertical stud of the tie rod end). c. With a pry bar placed between the steering linkage and the axle tube, pry upwards while measuring the amount of joint travel (wear). d. Measure the amount of wear in the other outer tie rod end joint. e. If wear (joint travel) in either outer tie rod end is greater than 1.15 mm (0.045 in.), then replace the worn tie rod end. 8. Verify the torque on each outer tie rod end stud nut. The nut should be tightened to 122 Nm (90 ft. lbs.). 9. Make sure any worn outer tie rod ends have been replaced before proceeding further. 10. Verify all other steering linkage connections are tightened to their torque specifications. 11. Grease both outer tie rod ends (even if the outer tie rod is new). Apply sufficient grease to each tie rod end until grease is seen purging from the joint at the dust seal. 12. Align the vehicle front end. Adjust to specifications. 13. Road test the vehicle and verify the shimmy condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Ride Height Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Ride Height > Page 2565 Alignment: Specifications Wheel Alignment ALIGNMENT SPECIFICATIONS NOTE: All alignment specifications are in degrees. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Description Alignment: Description and Operation Description DESCRIPTION NOTE: Suspension components with rubber/urethane bushings should be tightened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort could be affected and premature bushing wear may occur. Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe. CAUTION: Never attempt to modify suspension or steering components by heating or bending. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Description > Page 2568 Alignment: Description and Operation Operation OPERATION - CASTER is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides less positive caster. Tilting the top of the knuckle rearward provides more positive caster. Positive caster promotes directional stability. This angle enables the front wheels to return to a straight ahead position after turns - CAMBER is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire - TOE is the difference between the leading inside edges and trailing inside edges of the front tires. Wheel toe position out of specification cause's unstable steering, uneven tire wear and steering wheel off- center. The wheel toe position is the final front wheel alignment adjustment - THRUST ANGLE is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 2569 Alignment: Testing and Inspection PRE-ALIGNMENT INSPECTION Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to Suspension and Steering System Diagnosis Chart below for additional information. See: Steering and Suspension/Steering/Testing and Inspection/Symptom Related Diagnostic Procedures 1. Inspect tires for size, air pressure and tread wear. 2. Inspect front wheel bearings for wear. 3. Inspect front wheels for excessive radial or lateral runout and balance. 4. Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding. 5. Inspect suspension components for wear and noise. 6. Road test the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 2570 Suspension And Steering System Diagnosis (Part 1) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 2571 Suspension And Steering System Diagnosis (Part 2) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber And Caster Adjustment Alignment: Service and Repair Camber And Caster Adjustment CAMBER AND CASTER ADJUSTMENT Camber and caster angle adjustments involve changing the position of the lower control arm (2) in conjunction with the slotted holes in the frame brackets (1). Vehicle should be at normal ride height. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber And Caster Adjustment > Page 2574 Alignment: Service and Repair Toe Adjustment TOE ADJUSTMENT The wheel toe position adjustment is the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. 2. Loosen the tie rod jam nuts (1). NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. 3. Adjust the wheel toe position by turning the inner tie rod (2) as necessary. 4. Tighten the tie rod jam nut (1) to 127 Nm (94 ft. lbs.). 5. Verify the specifications 6. Turn off engine. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber And Caster Adjustment > Page 2575 Alignment: Service and Repair Camber, Caster And Toe Adjustment CAMBER, CASTER AND TOE ADJUSTMENT Camber and caster angle adjustments involve changing the position of the lower control arm with the slots in the frame brackets (1). CASTER Moving the front or rear position of the lower control arm in or out, will change the caster angle and camber angle significantly. To maintain the camber angle while adjusting caster, move one pivot bolt of the lower control arm in or out. Then move the other pivot bolt of the lower control arm in the opposite direction. To increase positive caster angle, move the rear position of the lower control arm inward (toward the engine). Move the front of the lower control arm outward (away from the engine) slightly until the desired camber angle is obtained. CAMBER Move both pivot bolts of the lower control arm together in or out. This will change the camber angle significantly and little effect on the caster angle. After adjustment is made tighten the lower control arm nuts to proper torque specification. TOE ADJUSTMENT The wheel toe position adjustment is the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. 2. Loosen the tie rod jam nuts (1). NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber And Caster Adjustment > Page 2576 3. Adjust the wheel toe position by turning the inner tie rod (2) as necessary. 4. Tighten the tie rod jam nut (1) to 127 Nm (94 ft. lbs.). 5. Verify the specifications 6. Turn off engine. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber And Caster Adjustment > Page 2577 Alignment: Service and Repair Alignment Link/Coil Suspension ALIGNMENT LINK/COIL SUSPENSION Before each alignment reading the vehicle should be jounced (rear first, then front). Grasp each bumper at the center and jounce the vehicle up and down several times. Always release the bumper in the down position. Set the front end alignment to specifications while the vehicle is in its NORMALLY LOADED CONDITION. CAMBER: The wheel camber angle is preset and is not adjustable. CASTER: Check the caster of the front axle for correct angle. Be sure the axle is not bent or twisted. Road test the vehicle and make left and right turn. Observe the steering wheel return-to-center position. Low caster will cause poor steering wheel returnability. Caster can be adjusted by rotating the cams (3) on the lower suspension arm. TOE POSITION: The wheel toe position adjustment should be the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Center and Secure the steering wheel and turn off engine. 2. Loosen the adjustment sleeve clamp bolts. 3. Adjust the right wheel toe position with the drag link. Turn the sleeve until the right wheel is at the correct TOE-IN position. Position clamp bolts to their original position and tighten to specifications. Make sure the toe setting does not change during clamp tightening. 4. Adjust left wheel toe position with tie rod at left knuckle. Turn the sleeve until the left wheel is at the correct TOE-IN position. Position clamp bolts to their original position and tighten to specifications. Make sure the toe setting does not change during clamp tightening. NOTE: Toe setting will change during tightening, Make sure to verify reading after tightening. 5. Verify the right toe setting and a straight steering wheel. 6. Road test the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber And Caster Adjustment > Page 2578 Alignment: Service and Repair Curb Height Measurement (HD) CURB HEIGHT MEASUREMENT (HD) The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load. Inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring is weak. 1. Front 4X2 On each side of the vehicle, measure the distance from the top of the jounce bumper flange (2) to the bottom of the frame rail (1). 2. Front 4X4 On each side of the vehicle, measure the distance from the top of the axle (2) to the bottom of the jounce bumper flange (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber And Caster Adjustment > Page 2579 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber And Caster Adjustment > Page 2580 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL PRESSURES Fuel Pump/Gear Pump (low pressure) ................................................................................................................................ 551.5 - 1241 KPA (80 - 180 psi) Injection Pump ..................................................................................................................................... ............................ 200 - 1800 bar (2900 - 26107 psi) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test Fuel Pressure: Testing and Inspection Fuel Pump Return Flow Test *FUEL PUMP RETURN FLOW TEST 1. FUEL PUMP RETURN FLOW TEST Using the scan tool, idle the engine and measure the rail pressure and determine if the rail pressure is excessive (above 185,00 kpa/26,831 psi). If it is, troubleshoot for excessive rail pressure first. Remove the banjo bolt from the pressure-limiting valve on the fuel rail. Install fuel system test fitting 9013 into the pressure-limiting valve. Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose into a container Perform the tests listed below to determine if the pressure-limiting valve is leaking. a. Operate the engine at idle and watch for fuel flow into the fuel container. b. Operate the engine at idle and actuate the high pressure safety valve test with the scan tool. Watch for fuel flow into the fuel container. If fuel flows into the fuel container, replace the pressure-limiting valve. If fuel does not leak from the pressure-limiting valve, the test is complete. NOTE: Do not drive the vehicle with any portion of this test kit installed Operate the engine until the engine is at operating temperature. Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing Install fuel system test fitting 9012 in place of the banjo connector. Install a piece of fuel line onto the test fitting and put the open end into the graduated cylinder . Start the engine and let it idle for one minute. Measure the amount of fuel in the graduated cylinder. If the flow is less than 1000ml/minute at idle, the test has successfully passed. If the flow is greater than 1000ml/minute at idle, replace the fuel injection pump. Retest to confirm repair. View Repair Repair - Test Complete. - Perform POWERTRAIN VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 2587 Fuel Pressure: Testing and Inspection High Pressure Fuel Pump Performance Test *HIGH PRESSURE FUEL PUMP PERFORMANCE TEST If the engine will run do the following: 1. Monitor rail pressure with scan tool while the engine is at idle. 2. Compare the fuel pressure set point with the actual fuel pressure reading. 3. If actual fuel pressure reading fluctuates more than ± 500 psi from the set point, then replace the Fuel Control Actuator (FCA). NOTE: After the actuator is removed, check for debris or corrosion on the FCA. If debris or corrosion is found, replace the entire Fuel Injection Pump. 4. Turn off engine. 5. Disconnect the FCA harness 6. Disconnect high pressure fuel line from fuel rail and route the high pressure fuel line into a graduated cylinder. 7. Crank the engine until fuel exits this line. This will not be high pressure fuel. 8. Crank the engine for three (3) 10 second intervals (Note: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter). Fuel flow specification s based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL If the engine is a no start do the following: 1. Remove fuel pump to rail high pressure fuel line. 2. Inspect the fuel pump outlet port for rust, debris, or other signs of contamination. 3. Replace pump if any contamination is found. Check for source of water in fuel or debris in fuel to prevent future complaints. If no contamination is found continue to step 4. 4. Disconnect the Fuel Control Actuator (FCA). 5. Disconnect the high pressure fuel line from the fuel rail and route the high pressure fuel line to a graduated cylinder. 6. Crank the engine until fuel exits this line. This will not be high pressure fuel. 7. Crank the engine for three (3) 10 seconds intervals. NOTE: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter. Fuel flow specification's based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 2588 Fuel Pressure: Testing and Inspection In-Tank Fuel Lift Pump Flow/Diagnostic Test Procedure *IN-TANK FUEL LIFT PUMP FLOW/DIAGNOSTIC TEST PROCEDURE 1. Using the Scan tool, check for DTCs. Troubleshoot any active DTCs before performing this test. 2. Disconnect the wiring harness from the lift pump at the fuel tank module connector and inspect the pins for damage. Fix or replace any damaged component. 3. Connect a voltmeter between the fuel lift pump supply and return pins at the fuel tank module connector. 4. Turn the ignition to the on position. Use the Scan tool to actuate the fuel lift pump, record the voltage on the voltmeter. 5. If the voltage is greater than 11.5 volts, go to step 14. If the voltage is less than 11.5 volts, go to step 6 6. Using a voltmeter, measure the battery voltage to determine that the voltage is greater than 11.5 volts. If the voltage is greater than 11.5 volts, go to step 7. If the voltage is not greater than 11.5 volts, troubleshoot for low battery voltage. 7. Remove the fuel lift pump relay from the PDC. Use a voltmeter to measure the voltage at the fuel lift pump relay voltage supply pin in the PDC. If the voltage is greater than 11.5 volts, go to step 8. If the voltage is not greater than 11.5 volts, fix or replace the harness. 8. Remove the fuel lift pump relay from the PDC. Install a spare relay in place of the fuel lift pump relay. Using the Scan tool, actuate the fuel lift pump. Use a voltmeter to measure the voltage between the fuel lift pump supply and return pins at the fuel tank module connector while the fuel lift pump is actuated. If the voltage is greater than 11.5 volts, replace the fuel lift pump relay. If the voltage is not greater than 11.5 volts, go to step 9. 9. Disconnect the wiring harness from the fuel tank module. Remove the lift pump relay from the PDC. Using an Ohmmeter, measure the resistance of the fuel lift pump power supply wire between the PDC relay output pin and the fuel tank module connector. If the resistance is less than 10 ohms, go to step 10. If it is greater than 10 ohms, fix or replace the harness. 10. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using a voltmeter, measure the voltage between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the voltage is less than 1 volt, go to step 11. If the voltage is greater than 1 volt, fix or replace the harness. 11. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using an ohmmeter, measure the resistance between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the resistance is less than 10 ohms, fix or replace the harness. If the resistance is greater than 10 ohms, go to step 12. 12. Disconnect the wiring harness from the fuel tank module. Using an Ohmmeter, measure the resistance of the fuel lift pump ground wire between the fuel tank module connector and battery negative. If the resistance is less than 10 ohms, go to step 13. If the resistance is greater than 10 ohms, fix or replace the harness. 13. Disconnect the wiring harness from the fuel tank module. Using a voltmeter, measure the voltage between the fuel lift pump ground wire and battery negative. If the voltage is less than 1 volt, go to step 14. If the voltage is greater than 1 volt, fix or replace the harness. 14. Reconnect the lift pump connector. FLOW TEST. 1. Remove the fuel pump supply banjo fitting from the fuel injection pump. 2. Install fuel system test fitting 9863 onto the end of the quick connect line going to the fuel injection pump. 3. Connect one end of a section of fuel hose to the test fitting. 4. Put the other end of the fuel hose into an empty fuel container. 5. Use the scan tool to actuate the fuel lift pump. 6. While the lift pump is running, move the fuel hose from the fuel canister into a 1000ml graduated cylinder for 10 seconds. 7. Read and record the amount of fuel in the graduated cylinder after 10 seconds. 8. If you have more than 570ml in the graduated cylinder after 10 seconds, the test has successfully passed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 2589 9. If you have less than 570ml of fuel in the graduated cylinder, inspect the fuel supply line from the fuel tank to the fuel filter housing and the fuel supply line between the fuel filter housing and the high pressure fuel pump for signs of damage, replace as necessary. If no damage is found, replace the fuel filter and retest. 10.Verify the Screened Banjo Bolt at the outlet of the fuel filter is free of debris. If debris is found, rinse screen with water, blow dry and reinstall. Retest vehicle. If flow meets specification then trace back the source of debris, if flow is still below spec repair damaged component. 11. If reading is still less than 570ml in 10 seconds, remove the fuel tank and fuel tank module. Inspect for damage and/or debris in and around the fuel tank module. If module is damaged, replace and retest. 12. If the module is not damaged, replace the fuel lift pump and retest to confirm fix. Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal Air Filter Element: Service and Repair Removal REMOVAL Testing Air Cleaner Element using Filter Minder(TM) Do not attempt to unnecessarily remove top of air cleaner housing for air cleaner element inspection on diesel engines. The air cleaner (filter) housing (5) is equipped with an air Filter Minder(TM) gauge (3). This air flow restriction gauge will determine when air cleaner element is restricted and should be replaced. The Filter Minder(TM) (5) consists of a diaphragm and calibrated spring sealed inside of a plastic housing. A yellow colored disc (2) attached to diaphragm moves along a graduated scale on side of Filter Minder. After the engine has been shut off, a ratcheting device located within Filter Minder will hold yellow disc at highest restriction that air cleaner element has experienced. A drop in air pressure due to an air cleaner element restriction moves diaphragm and yellow disc will indicate size of air drop. CAUTION: Certain engine degreasers or cleaners may discolor or damage plastic housing of Filter Minder. Cover and tape Filter Minder if any engine degreasers or cleaners are to be used. To test, turn engine off. If yellow disc (2) has reached red colored zone (3) on graduated scale, air cleaner element should be replaced. Refer to Removal / Installation. Resetting Filter Minder: After air cleaner (filter) element has been replaced, press rubber button on top of Filter Minder. This will allow yellow Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 2598 colored disc to reset. After button has been pressed, yellow disc should spring back to UP position. If Filter Minder gauge has reached red colored zone, and after an examination of air cleaner (filter) element, element appears to be clean, high reading may be due to a temporary condition such as snow build-up at air intake. Temporary high restrictions may also occur if air cleaner (filter) element has gotten wet such as during a heavy rain or snow. If this occurs, allow element to dry out during normal engine operation. Reset rubber button on top of Filter Minder and retest after element has dried. Filter Removal 1. The housing cover is equipped with spring clips and is hinged with plastic tabs. Unlatch clips from top of air cleaner housing and tilt housing cover up for cover removal. 2. Remove air cleaner element from air cleaner housing (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 2599 Air Filter Element: Service and Repair Installation INSTALLATION 1. Before installing new air cleaner element (filter), clean inside of air cleaner housing. 2. Position air cleaner cover to tabs on front of air cleaner housing. Latch spring clips to seal cover to housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit Fuel Filter: Technical Service Bulletins Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit NUMBER: 14-004-11 GROUP: Fuel System DATE: April 01, 2011 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-002-10, DATED FEBRUARY 11, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE NEW PARTS. SUBJECT: Heavy Duty Filtration MOPAR Retrofit or Add On Parts Available MODELS: 2003 - 2009 (D1/DH/DR) Ram Truck (2500/3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH/DR vehicles equipped with a 5.9L Cummins engine built from 2003 model year (sales codes ETH, ETC) and DC/DH/D1/vehicles equipped with a 6.7L Cummins engine built from 2007 model year (sales code ETJ). DISCUSSION: Several fuel system add-on or retrofit parts are available to enhance the filtering capability for customers exposing their vehicles to extremely dirty conditions. Description of parts available for Cummins diesel equipped vehicles are listed below: ^ **Severe duty, frame mounted fuel filter** (application for 2004.5 - 2009 Pickup & 2007 - 2010 Cab Chassis DC). ^ 6.7L up-graded (5 & 10 micron filter-in-filter) fuel filter to retrofit earlier models (shell and element). ^ 6.7L Element only, fuel filter. ^ 5.9L & 6.7L Add-on or up-graded fuel tank vent hose kit with vent cap. ^ Filter for fuel tank vent hose, (replaces vent cap). ^ 5.9L up-graded air filter. This filter is similar in design to the current 6.7L air filter. NOTE: Do not sell p/n 05183410AA fuel filter for (bottom load style) 6.7L engines. Use 68061633AA shell and filter. NOTE: The maintenance intervals for the fuel filter(s) is 15,000 miles, 400 engine hours or 12 Months, (whichever occurs first) or more often as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 2604 PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 2605 Fuel Filter: Technical Service Bulletins Fuel System - Severe Duty Filtration Kit Availability NUMBER: 14-001-09 GROUP: Fuel DATE: January 24, 2009 SUBJECT: Severe Duty Fuel Filtration Mopar Add On Kit Available MODELS: 2005 - 2009 (D1/DH) Ram Truck (2500/3500 Pick Up) 2007 - 2009 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH vehicles equipped with a 5.9L Cummins engine built from 2005 model year and D1/DH/DC vehicles equipped with a 6.7L Cummins engine built from 2007 model year. DISCUSSION: A frame mounted supplemental filter kit is now available for the vehicles listed above. This kit includes complete instructions (K6855569AC) with all necessary components and wiring to upgrade fuel filtering to a severe duty rating. NOTE: The maintenance intervals for the fuel filters (on engine filter and added chassis mounted severe duty fuel filtration kit filter) are 15,000 miles. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 2606 Fuel Filter: Technical Service Bulletins Diesel Fuel System - Fuel/Filtering Requirements NUMBER: 14-007-06 REV. A GROUP: Fuel DATE: September 02, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-007-06, DATED AUGUST 25, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL INFORMATION REGARDING FUELING OF EARLY BUILT 2007 RAM TRUCK CAB AND CHASSIS (DC) VEHICLES. SUBJECT: Fuel And Fuel Filtering Requirements For Cummins 5.9L And 6.7L Engines OVERVIEW: This bulletin involves a discussion regarding fuel system requirements. MODELS: 2006 - 2007 (DH/D1/DC) Ram Truck (Heavy Duty) NOTE: This bulletin applies to vehicles equipped with a 5.9L High Output or a 6.7L Cummins Turbo-Diesel Engine (sales codes ETH or ETJ respectively) that were built on or after March 07, 2006 (MDH 0307XX). DISCUSSION: Current Fuel Systems: - For the diesel engine system to operate at its peak performance a high level of fuel quality must be maintained. Emission control and fuel delivery systems have advanced significantly. Care must be taken to insure that the fuel that is delivered to the engine fuel injection system is of the highest quality possible and free of contaminants. - Significant components to fuel quality are: the initial quality of the fuel (as dispensed from the service station fuel pump or bulk storage), on-vehicle fuel storage, and the on-vehicle fuel filtering of the diesel fuel prior to the fuel injection process. - Refer to the Owners Manual for fuel and fuel system information. Proper Fuel And Fuel Quality: - Use good quality diesel fuel from a reputable supplier. It is recommended that purchase of diesel fuel should be made from a service station that is known to dispense a high volume of highway diesel fuel. - ** Ultra Low Sulfur Highway Diesel Fuel (15 ppm of sulfur or less and meeting ASTM D975 grade 5-15) is required for use in Dodge Ram Trucks equipped with a 6.7L diesel engine. ** - ** The 2007 Ram Truck Cab and Chassis (DC) vehicle is equipped with a 6.7L diesel engine. This vehicle is to use Ultra Low Sulfur Highway Diesel Fuel. Due to limited availability of Ultra Low Sulfur Highway Diesel Fuel, during the initial production of this vehicle, Low Sulfur Highway Diesel Fuel (500 ppm of sulfur or less) may be used ONLY until Ultra Low Sulfur Highway Diesel fuel becomes readily available and fuel pumps that dispense Ultra Low Sulfur Highway Diesel Fuel are required to be labelled as such. This is expected to occur around October 15, 2006. ** - ** Ultra Low Sulfur Highway Diesel Fuel (preferred) or Low Sulfur Highway Diesel Fuel (500 ppm of sulfur or less) are required for use in Dodge Ram Trucks equipped with a 5.9L diesel engine. ** - A maximum blend of 5% biodiesel (B5) is acceptable as long as the biodiesel mixture meets ASTM specification D-975, D-975 - grade 5-15, and ASTM D6751. A biodiesel fuel blend that is higher than 5% is not acceptable without additional fuel processing because these higher percentage biodiesel blends contain excess amounts of moisture which exceed the water stripping capability of the on-engine final fuel filter. Should a higher percentage biodiesel fuels be used an auxiliary water stripping filter will be required. - A maximum blend of 20% biodiesel (B20) can be used by government, military, and commercial fleets who equip their vehicle(s) with an optional water separator, and adhere to the guidelines in the Department of Defense specification A-A-59693 (in addition to: ASTM specification D-975, D-975 - grade 5-15 and ASTM D6751) - Off-highway diesel fuel (i.e. farm or marine use diesel fuel) that does not meet Ultra Low Sulfur Highway or Low Sulfur Highway fuel specifications (as listed above) is NOT acceptable. Unknown sulfur and water content and unknown cetane number may adversely affect the performance of the Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 2607 engine and fuel injection system. - Fuel conditioners (additives) are not recommended and should not be required if you buy good quality fuel and follow cold weather advice supplied in the Owners Manual. Proper Bulk (Off-Vehicle) Fuel Storage: - Proper maintenance of stored fuel is essential. Diesel fuel is seldom entirely free of moisture. Fuel contaminated with moisture may develop a bacteria or "slime" that may restrict or block fuel filters and lines. - As diesel fuel is lighter than water, drain condensation no less than monthly from the diesel fuel supply/storage tanks. - Change the storage tank in-line filter regularly. This filter acts as the last filter prior to the diesel fuel entering the vehicle diesel fuel tank. Good quality diesel fuel is mandatory. If the storage tank does not have an in-line filter, then a in-line filter should be added. Refer to the table on the following page for recommended in-line filter specifications. Proper On-vehicle Fuel Storage And Filtering: - Proper on-vehicle fuel storage that prevents fuel contamination is important. - The original (OEM) vehicle fuel tank module (fuel pickup) filter performs a primary filtering of the on-vehicle diesel fuel as the fuel leaves the fuel tank and enters the fuel lines. - On-vehicle auxiliary diesel fuel tanks are often added by the vehicle owner to extend vehicle driving range. Auxiliary fuel tank systems must protect the quality of the diesel fuel just as well as the originally equipped (OEM) fuel tank that came with the vehicle when it was new. - On-vehicle auxiliary diesel fuel storage tanks must have a primary fuel filter to prevent contamination and moisture accumulation. Refer to the table on the following page for recommended filter specifications. - The prevention of moisture in the fuel system, the prevention of fuel stagnation, and the use of a primary fuel filter should all be considered in the purchase, installation, and maintenance of any auxiliary on-vehicle diesel fuel tank. Proper On-vehicle Final Fuel Filtering: - The large fuel filter mounted at the engine is the final fuel filter, water separator, fuel heater, and water drain. This filter is the final 'line of defense" when maintaining a high level of fuel quality. If the diesel fuel is contaminated or contains moisture, the engine mounted fuel filter system is the last chance to affect possible correction. - The quality of the fuel, its prior storage, and fuel handling prior to the final filter all have a significant impact on the amount of contamination and moisture entering the final fuel filter. - It is important to drain accumulated moisture/water at least monthly from the final fuel filter. Do not wait until the 'Water In Fuel" indicator illuminates before performing this maintenance. - Maintenance on the final fuel filter / water separator is important. Follow the maintenance schedule per the Owners Manual. Replace the filter more frequently if highly contaminated or high moisture content fuel is encountered. - On a 5.9L engine, if the final fuel filter is replaced due to a high moisture content diesel fuel, verify that the water sensor probes in the final filter have been cleaned. Excessive moisture may contaminate the sensor sensing probes. The 6.7L engine includes a new water-in-fuel sensor with the new final fuel filter element. - The final fuel / water separator filter must meet or exceed OEM specifications. Some aftermarket filters may not meet OEM specifications. - The final fuel I water separator filter must meet or exceed the filtration specifications listed in the table shown. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 2608 - Final fuel / water separator filters that meet the above specifications are approved for use on Cummins 5.9L and 6.7L diesel engines. - The use of non-approved fuel filters will result in engine performance deterioration, and/or possible progressive damage to the engine from foreign particle ingestion, and/or fuel system component corrosion. - It is recommended that customers use the MOPAR approved or Cummins Equivalent fuel filters to protect the engine from debris and water contamination. - The following final fuel / water separator filters are known to meet or exceed the specifications listed in the table above. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Description and Operation > Description Fuel Filter: Description and Operation Description DESCRIPTION The fuel filter/water separator assembly is located on left side of engine above the starter motor. The assembly also includes the fuel heater, water drain valve, Water-In-Fuel (WIF) sensor and a quick-connect fittings attached at the side of the fuel filter canister. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Description and Operation > Description > Page 2611 Fuel Filter: Description and Operation Operation OPERATION The fuel filter/water separator protects the fuel injection pump by removing water and contaminants from the fuel. The construction of the filter/separator allows fuel to pass through it, but helps prevent moisture (water) from doing so. Moisture collects at the bottom of the filter. Refer to the maintenance schedules for the recommended fuel filter replacement intervals. For draining of water from canister, refer to Fuel/Water Separator Removal. There is a screened quick-connect fitting that is attached at the side of the fuel filter canister. It provides additional filtering for the high pressure fuel system components. A Water-In-Fuel (WIF) sensor is attached to the bottom of fuel filter element. The fuel heater is installed into the side of the filter/separator housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal Fuel Filter: Service and Repair Removal REMOVAL Refer to maintenance schedules for recommended fuel filter replacement intervals. Draining water from fuel filter canister: The housing drain valve (3) serves two purposes. One is to partially drain the filter housing of excess water. The other is to partially drain the housing for fuel filter or heater element replacement. The filter housing (1) should be partially drained whenever the water-in-fuel warning lamp remains illuminated. (Note that lamp will be illuminated for approximately two seconds when ignition key is initially placed in ON position for a bulb check). 1. A drain hose (4) is located at the bottom of drain valve. Place drain pan under drain hose. 2. With engine not running, rotate drain valve (3) approximately two revolutions to open it. Leave open until all water and contaminants have been removed and clean fuel exits. Hand tighten drain valve after tightening. 3. If fuel heater element is being replaced, drain housing completely. Dispose of mixture in drain pan according to applicable regulations. 4. After draining operation, close and tighten drain valve (3). 5. Fuel Filter Replacement: a. Remove left front tire/wheel. b. Remove left front wheel splash shield. c. Clean all debris from around filter canister (1) and canister head. d. Disconnect WIF sensor electrical connector (5). e. Open drain valve (3) two complete revolutions. Drain approximately 1 cup of fuel into a waste canister. Dispose of fuel according to environmental regulations. f. Remove drain hose (4) from drain valve (3). g. Use an oil filter type wrench to loosen filter (1). Continue removing filter by hand. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 2614 6. After fuel filter removal, also check and clean secondary filter screen. Press button (2) on quick-connect fitting. Disconnect fitting (1) from fitting (3). Unscrew fitting (3) from canister head to expose screen. 7. Clean screen (5) and check condition of O-ring (6). 8. Water-In-Fuel (WIF) Sensor Replacement: The WIF sensor (2) is located on the bottom of the fuel filter housing. The WIF sensor is not a separately serviceable item. If diagnostics have led you to replace this sensor, then the whole fuel filter assembly (1) needs to be changed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 2615 9. Fuel Heater Element Replacement: The heater element (2) is located in the fuel filter housing (4). a. Drain fuel filter. See previous steps. b. Disconnect electrical connector (1). c. Remove two mounting screws (3). d. Remove fuel heater (2). 10. Check condition of fuel heater O-ring (2). 11. Drain Valve Replacement: The Drain Valve is located on the bottom of the fuel filter. This is not a separately serviceable item. If replacement is necessary, replace the entire filter/filter canister assembly. 12. Fuel Filter Head (Housing) Replacement: a. If equipped, remove transmission dipstick tube from filter housing. b. Remove all low-pressure fuel lines at filter housing c. Remove housing from cylinder head. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 2616 Fuel Filter: Service and Repair Installation INSTALLATION Refer to maintenance schedules for recommended fuel filter replacement intervals. 1. Fuel Filter: CAUTION: Do not pre-fill the fuel filter with fuel. Severe damage to fuel system and injection system components may result. a. The engine has a self-priming low-pressure fuel system. b. Lubricate new fuel filter O-ring with clean engine oil. c. Position new fuel filter/canister assembly (1) to housing. d. Rotate fuel filter/canister assembly (1) until it comes to a hard stop. e. Tighten the filter element an additional half-inch of rotation. f. Connect WIF sensor electrical connector (5). g. Attach drain hose (4) to drain valve (3). h. Install left front tire/wheel. i. Install left front wheel splash shield. 2. Clean screen (5). 3. Check condition of new O-ring (6) and lubricate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 2617 4. Install screen assembly into housing and tighten fitting (3) to 20 ft. lbs. (27 Nm). 5. Connect quick connect fuel supply line (1) to fitting (3). 6. Fuel Heater Element: a. Check condition of O-ring (2). b. Lubricate new element O-ring before installation. 7. Install fuel heater element (3) into fuel filter housing (4). 8. Install two fuel heater mounting screws (3) and tighten to 60 in lbs. (6.8 Nm). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 2618 9. Connect electrical connector (1). 10. Fuel Filter Head (Housing): a. Install fuel filter head to cylinder head. Tighten bolts to 32 Nm (24 ft. lbs.) torque. b. Replace sealing washers on banjo bolts and install all low-pressure fuel lines to filter housing. Tighten banjo bolts to 24 Nm (18 ft. lbs.) torque. Tighten quick-connect fitting to 27 Nm (20 ft. lbs.) torque. c. If equipped, install transmission dipstick tube to filter housing. Tighten bolt to 10 Nm (8 ft. lbs.) torque. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications DESCRIPTION The cylinder block is constructed of cast iron. The casting is a skirted design which incorporates longitudal ribs for superior strength and noise reduction. The block incorporates metric straight thread o-ring fittings at lubrication oil access points. The engine is manufactured with the cylinders being a non-sleeved type cylinder. The cylinders are numbered front to rear ; 1 to 6. The firing order is 1-5-3-6-2-4. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > System Information > Specifications Ignition Timing: Specifications IGNITION TIMING Ignition timing is not adjustable on any engine. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure (Minimum) ...................................................................................................... ...................................................................... 350 psi. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2628 Compression Check: Testing and Inspection CYLINDER COMPRESSION/LEAKAGE TESTS CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure batteries are completely charged and the engine starter motor is in good operating condition. Otherwise, the indicated compression pressures may not be valid for diagnostic purposes. 1. Disconnect the fuel inlet line to the fuel filter housing. Plug the fuel line from the fuel tank. NOTE: Failure to plug fuel line will result in fuel leak. 2. Remove fuel transfer pump relay from PDC. 3. Start the engine and idle until the engine stalls (runs out of fuel). 4. Remove the cylinder head cover. 5. Remove the cylinder head cover carrier gasket. 6. Remove the high pressure fuel line between the cylinder head and fuel rail for the cylinder to be tested. Use tool 9864 to cap this fuel rail on the cylinder being tested. 7. Remove the fuel connector tube nut and fuel connector tube. 8. Remove the exhaust rocker lever. 9. Use Tool 9010 to remove the injector and copper sealing washer. 10. Install the exhaust rocker lever and torque to 36 Nm (27 ft. lbs.). 11. Cover the remaining rocker levers with clean shop towels to prevent any oil splatter under the hood. 12. Place a rag over the compression test tool fitting. Crank the engine for 2-3 seconds to purge any fuel that may have drained into the cylinder when the injector was removed. 13. Connect the compression test gauge. 14. Crank the engine for 5 seconds and record the pressure reading. Repeat this step three times and calculate the average of the three readings. NOTE: The minimum cylinder pressure is 350 psi. Cylinder pressure should be within 20% from cylinder to cylinder. 15. Combustion pressure leakage can be checked if cylinder pressure is below the specification. Perform the leakage test procedure on each cylinder according to the tester manufacturer instructions. 16. Upon completion of the test check and erase any engine related fault codes. CYLINDER COMBUSTION PRESSURE LEAKAGE The combustion pressure leakage test provides an accurate means for determining engine condition. Combustion pressure leakage testing will detect: - Exhaust and intake valve leaks (improper seating). - Leaks between adjacent cylinders or into water jacket. - Any causes for combustion/compression pressure loss 1. Start and operate the engine until it attains normal operating temperature. 2. Disconnect injector harness connectors. 3. Disconnect CCV tube and breather drain tube from valve cover. 4. Remove the cylinder head cover. 5. Disconnect harness from injectors. 6. Remove the cylinder head cover carrier gasket. 7. Bring the cylinder to be tested to TDC. 8. Remove the high pressure fuel line between the cylinder head and the fuel rail for the cylinder to be tested. 9. Install capping Tool 9864 onto the rail. 10. Remove the high pressure connector nut and high pressure connector with Tool 9015. 11. Remove the exhaust and intake rocker lever. 12. Use Tool # 9010 to remove the injector and copper sealing washer. 13. Install compression test Tool # 9007 into the injector bore. 14. Connect the leakage tester and perform the leakage test procedure on each cylinder according to the tester manufacturer's instructions. 15. Upon completion of the test check and erase any engine related fault codes. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments VALVE LASH ADJUSTMENT AND VERIFICATION NOTE: To obtain accurate readings, valve lash measurements AND adjustments should only be performed when the engine coolant temperature is less than 60°C (140°F). The 24-valve overhead system is a "low-maintenance" design. Routine adjustments are no longer necessary, however, measurement should still take place when troubleshooting performance problems, or upon completion of a repair that includes removal and installation of the valve train components or injectors. 1. Disconnect battery negative cables. 2. Remove cylinder head cover. 3. Using the crankshaft barring tool #7471-B, rotate crankshaft to align damper TDC mark to 12:00 o'clock position. a. If both number one cylinder rocker levers are loose, continue to next step. b. If both number one cylinder rocker levers are not loose, rotate crankshaft 360 degrees. 4. With the engine in this position, valve lash can be measured at the following rocker arms: INTAKE 1-2-4 / EXHAUST 1-3-5. Measure the valve lash by inserting a feeler gauge between the rocker arm socket and crosshead. Refer to VALVE LASH LIMIT CHART for the correct specifications. If the measurement falls within the limits, adjustment/resetting is not necessary. If measurement finds the lash outside of the limits, adjustment/resetting is required. Valve Lash Limit Chart Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > Page 2632 5. If adjustment/resetting is required, loosen the lock nut on rocker arms and turn the adjusting screw until the desired lash is obtained: - INTAKE 0.254 mm (0.010 in.) - EXHAUST 0.660 mm (0.026 in.) Tighten the lock nut to 24 Nm (18 ft. lbs.) and recheck the valve lash. 6. Using the crankshaft barring tool, rotate the crankshaft one revolution (360°) to align the damper TDC mark to the 12 o'clock position. 7. With the engine in this position, valve lash can be measured at the remaining rocker arms: INTAKE 3-5-6 / EXHAUST 2-4-6. Use the same method as above for determining whether adjustment is necessary, and adjust those that are found to be outside of the limits. 8. Install the cylinder head cover. 9. Connect the battery negative cables. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Timing Component Alignment Marks > Component Information > Locations Timing Component Alignment Marks: Locations Install the camshaft. Align the crankshaft and camshaft gear marks as shown. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams With A/C 1- Idler Pulley 2- Accessory Drive Belt 3- Power Steering Pulley 4- Radiator Fan Pulley 5Crankshaft Pulley 6- A/C Compressor Pulley 7- Accessory Drive Belt Tensioner 8- Generator 9Water Pump Pulley Without A/C Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 2639 1- Idler Pulley 2- Accessory Drive Belt 3- Power Steering Pulley 4- Radiator Fan Pulley 5Crankshaft Pulley 6- Accessory Drive Belt Tensioner 7- Generator 8- Water Pump Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 2640 Drive Belt: Description and Operation DESCRIPTION The accessory drive belt is a serpentine type belt. Satisfactory performance of these belts depends on belt condition and proper belt tension. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 2641 Drive Belt: Testing and Inspection DIAGNOSIS AND TESTING VISUAL DIAGNOSIS NOTE: Diesel Engine - If a belt is broken or frayed, inspect engine speed sensor (located near the crankshaft damper) for damage. When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib , are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing. Refer to ACCESSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis. NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 2642 Accessory Drive Belt Diagnosis Chart (Part 1) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 2643 Accessory Drive Belt Diagnosis Chart (Part 2) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Procedures Drive Belt: Procedures CLEANING Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and coolants before installing the drive belt. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Procedures > Page 2646 Drive Belt: Removal and Replacement Removal 5.9L/6.7L DIESEL Belt Routing-Diesel Engine Without A/C 1. A 1/2 inch square hole is provided in the automatic belt tensioner. Attach a 1/2 inch drive-long handle ratchet to this hole. BELT ROUTING-DIESEL WITH A/C 2. Rotate ratchet and tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt. 3. Remove belt from water pump pulley first. 4. Remove belt from vehicle. Installation 5.9L/6.7L DIESEL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Procedures > Page 2647 Belt Routing - DIESEL WITH A/C CAUTION: When installing the accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. 1. Position drive belt over all pulleys except water pump pulley. 2. Attach a 1/2 inch ratchet to tensioner. Belt Routing - DIESEL WITHOUT A/C 3. Rotate ratchet and belt tensioner clockwise. Place belt over water pump pulley. Let tensioner rotate back into place. Remove ratchet. Be sure belt is properly seated on all pulleys. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal Air Filter Element: Service and Repair Removal REMOVAL Testing Air Cleaner Element using Filter Minder(TM) Do not attempt to unnecessarily remove top of air cleaner housing for air cleaner element inspection on diesel engines. The air cleaner (filter) housing (5) is equipped with an air Filter Minder(TM) gauge (3). This air flow restriction gauge will determine when air cleaner element is restricted and should be replaced. The Filter Minder(TM) (5) consists of a diaphragm and calibrated spring sealed inside of a plastic housing. A yellow colored disc (2) attached to diaphragm moves along a graduated scale on side of Filter Minder. After the engine has been shut off, a ratcheting device located within Filter Minder will hold yellow disc at highest restriction that air cleaner element has experienced. A drop in air pressure due to an air cleaner element restriction moves diaphragm and yellow disc will indicate size of air drop. CAUTION: Certain engine degreasers or cleaners may discolor or damage plastic housing of Filter Minder. Cover and tape Filter Minder if any engine degreasers or cleaners are to be used. To test, turn engine off. If yellow disc (2) has reached red colored zone (3) on graduated scale, air cleaner element should be replaced. Refer to Removal / Installation. Resetting Filter Minder: After air cleaner (filter) element has been replaced, press rubber button on top of Filter Minder. This will allow yellow Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 2654 colored disc to reset. After button has been pressed, yellow disc should spring back to UP position. If Filter Minder gauge has reached red colored zone, and after an examination of air cleaner (filter) element, element appears to be clean, high reading may be due to a temporary condition such as snow build-up at air intake. Temporary high restrictions may also occur if air cleaner (filter) element has gotten wet such as during a heavy rain or snow. If this occurs, allow element to dry out during normal engine operation. Reset rubber button on top of Filter Minder and retest after element has dried. Filter Removal 1. The housing cover is equipped with spring clips and is hinged with plastic tabs. Unlatch clips from top of air cleaner housing and tilt housing cover up for cover removal. 2. Remove air cleaner element from air cleaner housing (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 2655 Air Filter Element: Service and Repair Installation INSTALLATION 1. Before installing new air cleaner element (filter), clean inside of air cleaner housing. 2. Position air cleaner cover to tabs on front of air cleaner housing. Latch spring clips to seal cover to housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair Chrysler provides no information on a Cabin Air Filter for this vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Crankcase Filter > Component Information > Description and Operation Crankcase Filter: Description and Operation DESCRIPTION The Closed Crankcase Ventilation System (CCV) consists of several parts to make it functional. One part is the filter. The filter is serviceable and prevents oil mist from entering the discharge tube of the CCV system. It is not cleaned, but replaced at 60,000 mile intervals. The crankcase breather assembly is integrated into the cylinder head cover (3) and is serviced separately. The external fittings (2) to the breather tube and breather drain tube are serviceable. The crankcase breather assembly is integrated into the cylinder head cover and corresponding breather cover. Crankcase gasses travel into the breather cavity under the breather cover where they pass through a filtering media (serviceable maintenance component) which separates the oil from the crankcase gasses. The oil drains back into the engine block through two hoses (2) on the left side of the engine. The crankcase gasses are directed through the Crankcase Depression Regulator (CDR) valve which allows the system to maintain a constant positive pressure in the crankcase. The CDR valve is a non-serviceable component located on the underside of the breather cover. Clean crankcase gasses flow from the CDR valve into the fresh air side of the turbocharger compressor. The closed crankcase ventilation valve is used to vent the crankcase gases back into the intake of engine. If the crankcase ventilation filter becomes too restrictive, under high intake vacuum situations, the closed crankcase ventilation prevents the engine from syphoning crankcase gases/oil from the crankcase of the engine. The closed crankcase ventilation valve is located under the crankcase ventilation filter cover at the top of the engine. TESTING 1. If troubleshooting high crankcase pressure, the following items can be causing the closed crankcase ventilation valve to close during engine Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Crankcase Filter > Component Information > Description and Operation > Page 2662 operation: High air intake restriction. Check for high intake restriction - A restricted crankcase ventilation filter. Change the filter - A malfunctioning or misassembled closed crankcase ventilation valve. Check the valve operation and change if necessary 2. The closed crankcase ventilation valve should allow crankcases gases to flow when the engine is not running and/or removed from the engine. NOTE: Application of air can be applied either to the inlet or outlet of the closed crankcase ventilation valve. 3. A small amount of air can be blown through the closed crankcase ventilation valve (less than 34 kPa [5 psi]) to check the closed crankcase ventilation valve. 4. If air does not go through the closed crankcase ventilation valve, replace the valve. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Crankcase Filter > Component Information > Service and Repair > Removal Crankcase Filter: Service and Repair Removal REMOVAL 1. Using hose clamp pliers, loosen the breather plumbing from the breather cover connections. 2. Carefully remove the breather hoses (2) from the breather cover assembly (3). 3. Remove the capscrews surrounding the parameter of the breather cover (3). 4. Separate the breather cover (3) assembly from the cylinder head cover (1). FILTER ELEMENT REMOVAL 1. With the breather cover removed, remove the filter element from the cylinder head cover cavity by lifting the element straight up from its sealing surface. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Crankcase Filter > Component Information > Service and Repair > Removal > Page 2665 Crankcase Filter: Service and Repair Installation FILTER ELEMENT INSPECTION 1. Inspect the crankcase breather assembly by ensuring the oil drain hoses are not kinked or cracked. 2. Inspect all external hose connections for signs of leakage, repair where necessary. Inspect the breather for cracks or damage. 3. Inspect the filter element sealing surface for gouges or cracks; this surface should be smooth and free of abrasions. FILTER ELEMENT INSTALLATION 1. Clean the filter sealing surface on the cylinder head cover with a clean shop towel. 2. Install the new filter element, lubrication of the new sealing surface is not recommended. 3. Press the new filter into the cylinder head cover cavity until fully seated. 4. Install the breather cover assembly. BREATHER COVER INSTALLATION 1. Inspect the filter element for proper installation. The filter should be completely seated around the circumference of the sealing surface. 2. Install the breather cover to the cylinder head cover. 3. Install the capscrews surrounding the breather cover. 4. Install the breather drain hoses onto the hose barbs. Do not damage or hose connection during installation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Fluid Filter - A/T: Service and Repair 68RFE Automatic Transmission FLUID AND FILTER REPLACEMENT REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. Transmission Filters - 4X4 Shown 9. Remove the screw holding the primary oil filter (1) to valve body. 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Inspect the oil filter seal in the bottom of the oil pump. If the seal is not installed completely in the oil pump, or is otherwise damaged, then remove and discard the oil filter seal from the bottom of the oil pump. If the seal is installed correctly and is in good condition, it can be reused. 12. If replacing the cooler return filter (2), use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the diagnosis information. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2670 Transmission Filters - 4X4 Shown CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 1. If necessary, install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with Installer 6960-A or another suitable tool (appropriately sized drift or socket, the butt end of a hammer etc.). 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold the primary oil filter (1) to valve body. Tighten screw to 4.5 Nm (40 in. lbs.) torque. 4. Install new cooler return filter (2) onto the transmission, if necessary. Torque the filter to 9.5 Nm (84 in.lbs.). 5. Place bead of Mopar(R) RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 12 Nm (105 in. lbs.) torque. 8. Lower vehicle and fill transmission with MOPAR(R) ATF +4. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2671 Fluid Filter - A/T: Service and Repair 48RE Automatic Transmission FLUID AND FILTER REPLACEMENT The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan (3). 3. Remove bolts holding front and sides of pan to transmission (1). 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan and reusable gasket (2) away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolt holding pan to transmission. 7. While holding pan level, lower pan and gasket away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screws holding filter (2) to valve body. 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used trans fluid and filter properly. INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2672 1. Position a new transmission oil filter (2) onto the valve body. 2. Install the screws to hold the filter to the valve body. Tighten the screws to 4 Nm (35 in.lbs.). 3. Clean the gasket surfaces of the transmission oil pan (3) and transmission pan rail. NOTE: The transmission pan oil gasket (2) is reusable. Inspect the sealing surfaces of the gasket. If the sealing ribs on both surfaces appear to be in good condition, clean the gasket of any foreign material and reinstall. 4. Position the oil pan gasket (2) onto the oil pan (3). 5. Position the oil pan and gasket onto the transmission and install several bolts to hold the pan and gasket to the transmission. 6. Install the remainder of the oil pan bolts. Tighten the bolts to 13.6 Nm (125 in.lbs.). 7. Lower vehicle and fill transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2673 Fluid Filter - A/T: Service and Repair AS68RC Automatic Transmission FLUID AND FILTER REPLACEMENT REMOVAL DRAIN PLUG 1. Raise vehicle. 2. Place a large diameter drain pan beneath the transmission pan. 3. Remove the drain plug bolt (1) and allow the oil to drain from the transmission pan. 4. Remove the drain pan bolts from the transmission case. 5. Remove the drain pan. TRANSMISSION OIL FILTER Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2674 6. Remove the transmission oil filter bolts (3). 7. Remove the transmission oil filter and O-ring seal from the valve body (1). INSPECTION OIL PAN MAGNETS Inspect bottom of pan, pick-up magnets (1) and magnetic drain plug (2) and fluid filter for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the diagnosis information. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2675 TRANSMISSION OIL FILTER 1. Lubricate the transmission oil filter seal with MOPAR(R) AS68RC ATF. 2. Install the new transmission oil filter (2) in position on valve body (1) and into the oil pump. 3. Install the transmission oil filter bolts (3). 4. Tighten bolts to 10 Nm ( 88 in.lbs. ) torque. 5. Install a new transmission oil pan gasket. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 7 Nm (62 in. lbs.) torque. DRAIN PLUG 8. Install transmission drain plug bolt (1). 9. Tighten oil pan drain plug to 27 Nm ( 20 ft.lbs) torque. 10. Lower vehicle and fill transmission with MOPAR(R) AS68RC ATF. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit Fuel Filter: Technical Service Bulletins Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit NUMBER: 14-004-11 GROUP: Fuel System DATE: April 01, 2011 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-002-10, DATED FEBRUARY 11, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE NEW PARTS. SUBJECT: Heavy Duty Filtration MOPAR Retrofit or Add On Parts Available MODELS: 2003 - 2009 (D1/DH/DR) Ram Truck (2500/3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH/DR vehicles equipped with a 5.9L Cummins engine built from 2003 model year (sales codes ETH, ETC) and DC/DH/D1/vehicles equipped with a 6.7L Cummins engine built from 2007 model year (sales code ETJ). DISCUSSION: Several fuel system add-on or retrofit parts are available to enhance the filtering capability for customers exposing their vehicles to extremely dirty conditions. Description of parts available for Cummins diesel equipped vehicles are listed below: ^ **Severe duty, frame mounted fuel filter** (application for 2004.5 - 2009 Pickup & 2007 - 2010 Cab Chassis DC). ^ 6.7L up-graded (5 & 10 micron filter-in-filter) fuel filter to retrofit earlier models (shell and element). ^ 6.7L Element only, fuel filter. ^ 5.9L & 6.7L Add-on or up-graded fuel tank vent hose kit with vent cap. ^ Filter for fuel tank vent hose, (replaces vent cap). ^ 5.9L up-graded air filter. This filter is similar in design to the current 6.7L air filter. NOTE: Do not sell p/n 05183410AA fuel filter for (bottom load style) 6.7L engines. Use 68061633AA shell and filter. NOTE: The maintenance intervals for the fuel filter(s) is 15,000 miles, 400 engine hours or 12 Months, (whichever occurs first) or more often as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 2680 PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 2681 Fuel Filter: Technical Service Bulletins Fuel System - Severe Duty Filtration Kit Availability NUMBER: 14-001-09 GROUP: Fuel DATE: January 24, 2009 SUBJECT: Severe Duty Fuel Filtration Mopar Add On Kit Available MODELS: 2005 - 2009 (D1/DH) Ram Truck (2500/3500 Pick Up) 2007 - 2009 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH vehicles equipped with a 5.9L Cummins engine built from 2005 model year and D1/DH/DC vehicles equipped with a 6.7L Cummins engine built from 2007 model year. DISCUSSION: A frame mounted supplemental filter kit is now available for the vehicles listed above. This kit includes complete instructions (K6855569AC) with all necessary components and wiring to upgrade fuel filtering to a severe duty rating. NOTE: The maintenance intervals for the fuel filters (on engine filter and added chassis mounted severe duty fuel filtration kit filter) are 15,000 miles. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 2682 Fuel Filter: Technical Service Bulletins Diesel Fuel System - Fuel/Filtering Requirements NUMBER: 14-007-06 REV. A GROUP: Fuel DATE: September 02, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-007-06, DATED AUGUST 25, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL INFORMATION REGARDING FUELING OF EARLY BUILT 2007 RAM TRUCK CAB AND CHASSIS (DC) VEHICLES. SUBJECT: Fuel And Fuel Filtering Requirements For Cummins 5.9L And 6.7L Engines OVERVIEW: This bulletin involves a discussion regarding fuel system requirements. MODELS: 2006 - 2007 (DH/D1/DC) Ram Truck (Heavy Duty) NOTE: This bulletin applies to vehicles equipped with a 5.9L High Output or a 6.7L Cummins Turbo-Diesel Engine (sales codes ETH or ETJ respectively) that were built on or after March 07, 2006 (MDH 0307XX). DISCUSSION: Current Fuel Systems: - For the diesel engine system to operate at its peak performance a high level of fuel quality must be maintained. Emission control and fuel delivery systems have advanced significantly. Care must be taken to insure that the fuel that is delivered to the engine fuel injection system is of the highest quality possible and free of contaminants. - Significant components to fuel quality are: the initial quality of the fuel (as dispensed from the service station fuel pump or bulk storage), on-vehicle fuel storage, and the on-vehicle fuel filtering of the diesel fuel prior to the fuel injection process. - Refer to the Owners Manual for fuel and fuel system information. Proper Fuel And Fuel Quality: - Use good quality diesel fuel from a reputable supplier. It is recommended that purchase of diesel fuel should be made from a service station that is known to dispense a high volume of highway diesel fuel. - ** Ultra Low Sulfur Highway Diesel Fuel (15 ppm of sulfur or less and meeting ASTM D975 grade 5-15) is required for use in Dodge Ram Trucks equipped with a 6.7L diesel engine. ** - ** The 2007 Ram Truck Cab and Chassis (DC) vehicle is equipped with a 6.7L diesel engine. This vehicle is to use Ultra Low Sulfur Highway Diesel Fuel. Due to limited availability of Ultra Low Sulfur Highway Diesel Fuel, during the initial production of this vehicle, Low Sulfur Highway Diesel Fuel (500 ppm of sulfur or less) may be used ONLY until Ultra Low Sulfur Highway Diesel fuel becomes readily available and fuel pumps that dispense Ultra Low Sulfur Highway Diesel Fuel are required to be labelled as such. This is expected to occur around October 15, 2006. ** - ** Ultra Low Sulfur Highway Diesel Fuel (preferred) or Low Sulfur Highway Diesel Fuel (500 ppm of sulfur or less) are required for use in Dodge Ram Trucks equipped with a 5.9L diesel engine. ** - A maximum blend of 5% biodiesel (B5) is acceptable as long as the biodiesel mixture meets ASTM specification D-975, D-975 - grade 5-15, and ASTM D6751. A biodiesel fuel blend that is higher than 5% is not acceptable without additional fuel processing because these higher percentage biodiesel blends contain excess amounts of moisture which exceed the water stripping capability of the on-engine final fuel filter. Should a higher percentage biodiesel fuels be used an auxiliary water stripping filter will be required. - A maximum blend of 20% biodiesel (B20) can be used by government, military, and commercial fleets who equip their vehicle(s) with an optional water separator, and adhere to the guidelines in the Department of Defense specification A-A-59693 (in addition to: ASTM specification D-975, D-975 - grade 5-15 and ASTM D6751) - Off-highway diesel fuel (i.e. farm or marine use diesel fuel) that does not meet Ultra Low Sulfur Highway or Low Sulfur Highway fuel specifications (as listed above) is NOT acceptable. Unknown sulfur and water content and unknown cetane number may adversely affect the performance of the Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 2683 engine and fuel injection system. - Fuel conditioners (additives) are not recommended and should not be required if you buy good quality fuel and follow cold weather advice supplied in the Owners Manual. Proper Bulk (Off-Vehicle) Fuel Storage: - Proper maintenance of stored fuel is essential. Diesel fuel is seldom entirely free of moisture. Fuel contaminated with moisture may develop a bacteria or "slime" that may restrict or block fuel filters and lines. - As diesel fuel is lighter than water, drain condensation no less than monthly from the diesel fuel supply/storage tanks. - Change the storage tank in-line filter regularly. This filter acts as the last filter prior to the diesel fuel entering the vehicle diesel fuel tank. Good quality diesel fuel is mandatory. If the storage tank does not have an in-line filter, then a in-line filter should be added. Refer to the table on the following page for recommended in-line filter specifications. Proper On-vehicle Fuel Storage And Filtering: - Proper on-vehicle fuel storage that prevents fuel contamination is important. - The original (OEM) vehicle fuel tank module (fuel pickup) filter performs a primary filtering of the on-vehicle diesel fuel as the fuel leaves the fuel tank and enters the fuel lines. - On-vehicle auxiliary diesel fuel tanks are often added by the vehicle owner to extend vehicle driving range. Auxiliary fuel tank systems must protect the quality of the diesel fuel just as well as the originally equipped (OEM) fuel tank that came with the vehicle when it was new. - On-vehicle auxiliary diesel fuel storage tanks must have a primary fuel filter to prevent contamination and moisture accumulation. Refer to the table on the following page for recommended filter specifications. - The prevention of moisture in the fuel system, the prevention of fuel stagnation, and the use of a primary fuel filter should all be considered in the purchase, installation, and maintenance of any auxiliary on-vehicle diesel fuel tank. Proper On-vehicle Final Fuel Filtering: - The large fuel filter mounted at the engine is the final fuel filter, water separator, fuel heater, and water drain. This filter is the final 'line of defense" when maintaining a high level of fuel quality. If the diesel fuel is contaminated or contains moisture, the engine mounted fuel filter system is the last chance to affect possible correction. - The quality of the fuel, its prior storage, and fuel handling prior to the final filter all have a significant impact on the amount of contamination and moisture entering the final fuel filter. - It is important to drain accumulated moisture/water at least monthly from the final fuel filter. Do not wait until the 'Water In Fuel" indicator illuminates before performing this maintenance. - Maintenance on the final fuel filter / water separator is important. Follow the maintenance schedule per the Owners Manual. Replace the filter more frequently if highly contaminated or high moisture content fuel is encountered. - On a 5.9L engine, if the final fuel filter is replaced due to a high moisture content diesel fuel, verify that the water sensor probes in the final filter have been cleaned. Excessive moisture may contaminate the sensor sensing probes. The 6.7L engine includes a new water-in-fuel sensor with the new final fuel filter element. - The final fuel / water separator filter must meet or exceed OEM specifications. Some aftermarket filters may not meet OEM specifications. - The final fuel I water separator filter must meet or exceed the filtration specifications listed in the table shown. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 2684 - Final fuel / water separator filters that meet the above specifications are approved for use on Cummins 5.9L and 6.7L diesel engines. - The use of non-approved fuel filters will result in engine performance deterioration, and/or possible progressive damage to the engine from foreign particle ingestion, and/or fuel system component corrosion. - It is recommended that customers use the MOPAR approved or Cummins Equivalent fuel filters to protect the engine from debris and water contamination. - The following final fuel / water separator filters are known to meet or exceed the specifications listed in the table above. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Description and Operation > Description Fuel Filter: Description and Operation Description DESCRIPTION The fuel filter/water separator assembly is located on left side of engine above the starter motor. The assembly also includes the fuel heater, water drain valve, Water-In-Fuel (WIF) sensor and a quick-connect fittings attached at the side of the fuel filter canister. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Description and Operation > Description > Page 2687 Fuel Filter: Description and Operation Operation OPERATION The fuel filter/water separator protects the fuel injection pump by removing water and contaminants from the fuel. The construction of the filter/separator allows fuel to pass through it, but helps prevent moisture (water) from doing so. Moisture collects at the bottom of the filter. Refer to the maintenance schedules for the recommended fuel filter replacement intervals. For draining of water from canister, refer to Fuel/Water Separator Removal. There is a screened quick-connect fitting that is attached at the side of the fuel filter canister. It provides additional filtering for the high pressure fuel system components. A Water-In-Fuel (WIF) sensor is attached to the bottom of fuel filter element. The fuel heater is installed into the side of the filter/separator housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Removal Fuel Filter: Service and Repair Removal REMOVAL Refer to maintenance schedules for recommended fuel filter replacement intervals. Draining water from fuel filter canister: The housing drain valve (3) serves two purposes. One is to partially drain the filter housing of excess water. The other is to partially drain the housing for fuel filter or heater element replacement. The filter housing (1) should be partially drained whenever the water-in-fuel warning lamp remains illuminated. (Note that lamp will be illuminated for approximately two seconds when ignition key is initially placed in ON position for a bulb check). 1. A drain hose (4) is located at the bottom of drain valve. Place drain pan under drain hose. 2. With engine not running, rotate drain valve (3) approximately two revolutions to open it. Leave open until all water and contaminants have been removed and clean fuel exits. Hand tighten drain valve after tightening. 3. If fuel heater element is being replaced, drain housing completely. Dispose of mixture in drain pan according to applicable regulations. 4. After draining operation, close and tighten drain valve (3). 5. Fuel Filter Replacement: a. Remove left front tire/wheel. b. Remove left front wheel splash shield. c. Clean all debris from around filter canister (1) and canister head. d. Disconnect WIF sensor electrical connector (5). e. Open drain valve (3) two complete revolutions. Drain approximately 1 cup of fuel into a waste canister. Dispose of fuel according to environmental regulations. f. Remove drain hose (4) from drain valve (3). g. Use an oil filter type wrench to loosen filter (1). Continue removing filter by hand. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Removal > Page 2690 6. After fuel filter removal, also check and clean secondary filter screen. Press button (2) on quick-connect fitting. Disconnect fitting (1) from fitting (3). Unscrew fitting (3) from canister head to expose screen. 7. Clean screen (5) and check condition of O-ring (6). 8. Water-In-Fuel (WIF) Sensor Replacement: The WIF sensor (2) is located on the bottom of the fuel filter housing. The WIF sensor is not a separately serviceable item. If diagnostics have led you to replace this sensor, then the whole fuel filter assembly (1) needs to be changed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Removal > Page 2691 9. Fuel Heater Element Replacement: The heater element (2) is located in the fuel filter housing (4). a. Drain fuel filter. See previous steps. b. Disconnect electrical connector (1). c. Remove two mounting screws (3). d. Remove fuel heater (2). 10. Check condition of fuel heater O-ring (2). 11. Drain Valve Replacement: The Drain Valve is located on the bottom of the fuel filter. This is not a separately serviceable item. If replacement is necessary, replace the entire filter/filter canister assembly. 12. Fuel Filter Head (Housing) Replacement: a. If equipped, remove transmission dipstick tube from filter housing. b. Remove all low-pressure fuel lines at filter housing c. Remove housing from cylinder head. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Removal > Page 2692 Fuel Filter: Service and Repair Installation INSTALLATION Refer to maintenance schedules for recommended fuel filter replacement intervals. 1. Fuel Filter: CAUTION: Do not pre-fill the fuel filter with fuel. Severe damage to fuel system and injection system components may result. a. The engine has a self-priming low-pressure fuel system. b. Lubricate new fuel filter O-ring with clean engine oil. c. Position new fuel filter/canister assembly (1) to housing. d. Rotate fuel filter/canister assembly (1) until it comes to a hard stop. e. Tighten the filter element an additional half-inch of rotation. f. Connect WIF sensor electrical connector (5). g. Attach drain hose (4) to drain valve (3). h. Install left front tire/wheel. i. Install left front wheel splash shield. 2. Clean screen (5). 3. Check condition of new O-ring (6) and lubricate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Removal > Page 2693 4. Install screen assembly into housing and tighten fitting (3) to 20 ft. lbs. (27 Nm). 5. Connect quick connect fuel supply line (1) to fitting (3). 6. Fuel Heater Element: a. Check condition of O-ring (2). b. Lubricate new element O-ring before installation. 7. Install fuel heater element (3) into fuel filter housing (4). 8. Install two fuel heater mounting screws (3) and tighten to 60 in lbs. (6.8 Nm). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Removal > Page 2694 9. Connect electrical connector (1). 10. Fuel Filter Head (Housing): a. Install fuel filter head to cylinder head. Tighten bolts to 32 Nm (24 ft. lbs.) torque. b. Replace sealing washers on banjo bolts and install all low-pressure fuel lines to filter housing. Tighten banjo bolts to 24 Nm (18 ft. lbs.) torque. Tighten quick-connect fitting to 27 Nm (20 ft. lbs.) torque. c. If equipped, install transmission dipstick tube to filter housing. Tighten bolt to 10 Nm (8 ft. lbs.) torque. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Removal Oil Filter: Service and Repair Removal REMOVAL 1. Clean the area around the oil filter head. Remove the filter from below using a cap-style filter wrench. 2. Clean the gasket surface of the filter head. The filter canister O-Ring seal can stick on the filter head. Make sure it is removed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Removal > Page 2699 Oil Filter: Service and Repair Installation INSTALLATION 1. Fill the oil filter element with clean oil before installation. Use the same type oil that will be used in the engine. 2. Apply a light film of lubricating oil to the sealing surface before installing the filter. CAUTION: Mechanical over-tightening may distort the threads or damage the filter element seal. 3. Install the filter until it contacts the sealing surface of the oil filter adapter. Tighten filter an additional 1/2 turn. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service Precautions > Warning Hose/Line HVAC: Service Precautions Warning WARNING WARNING: The A/C system contains refrigerant under high pressure. Repairs should only be performed by qualified service personnel. Serious or fatal injury may result from improper service procedures. WARNING: Avoid breathing the refrigerant and refrigerant oil vapor or mist. Exposure may irritate the eyes, nose, and/or throat. Wear eye protection when servicing the A/C refrigerant system. Serious eye injury can result from direct contact with the refrigerant. If eye contact occurs, seek medical attention immediately. WARNING: Do not expose the refrigerant to open flame. Poisonous gas is created when refrigerant is burned. An electronic leak detector is recommended. Serious or fatal injury may result from improper service procedures. WARNING: If accidental A/C system discharge occurs, ventilate the work area before resuming service. Large amounts of refrigerant released in a closed work area will displace the oxygen and cause suffocation and serious or fatal injury. WARNING: The evaporation rate of R-134a refrigerant at average temperature and altitude is extremely high. As a result, anything that comes in contact with the refrigerant will freeze. Always protect the skin or delicate objects from direct contact with the refrigerant. WARNING: The R-134a service equipment or the vehicle refrigerant system should not be pressure tested or leak tested with compressed air. Some mixtures of air and R-134a have been shown to be combustible at elevated pressures. These mixtures are potentially dangerous, and may result in fire or explosion causing property damage and serious or fatal injury. WARNING: The engine cooling system is designed to develop internal pressures up to 145 kilo pascals (21 pounds per square inch). Do not remove or loosen the coolant pressure cap, cylinder block drain plugs, radiator drain, radiator hoses, heater hoses, or hose clamps while the engine cooling system is hot and under pressure. Allow the vehicle to cool for a minimum of 15 minutes before opening the cooling system for service. Failure to observe this warning can result in serious burns from the heated engine coolant. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service Precautions > Warning > Page 2705 Hose/Line HVAC: Service Precautions Caution CAUTION CAUTION: Never add R-12 to a refrigerant system designed to use R-134a. Do not use R-12 equipment or parts on an R-134a A/C system. These refrigerants are not compatible and damage to the A/C system will result. CAUTION: Never use R-12 refrigerant oil in an A/C system designed to use R-134a refrigerant oil. These refrigerant oils are not compatible and damage to the A/C system will result. CAUTION: The use of A/C system sealers may result in damage to A/C refrigerant recovery/evacuation/recharging equipment and/or A/C system. Many federal, state/provincial and local regulations prohibit the recharge of A/C systems with known leaks. DaimlerChrysler recommends the detection of A/C system leaks through the use of approved leak detectors and fluorescent leak detection dyes. Vehicles found with A/C system sealers should be treated as contaminated and replacement of the entire A/C refrigerant system is recommended. A/C systems found to be contaminated with A/C system sealers, A/C stop-leak products or seal conditioners voids the warranty for the A/C system. CAUTION: Recover the refrigerant before opening any fitting or connection. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant. CAUTION: If equipped, do not remove the secondary retention clip from any spring-lock coupler connection while the refrigerant system is under pressure. Recover the refrigerant before removing the secondary retention clip. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant. CAUTION: The internal parts of the A/C system will remain stable as long as moisture-free refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture or air can upset the chemical stability. This may cause operational troubles or even serious damage if present in more than very small quantities. Before disconnecting a component, clean the outside of the fittings thoroughly to prevent contamination from entering the refrigerant system. Keep service tools and the work area clean. Do not open the refrigerant system or uncap a replacement component until you are ready to service the system. Immediately after disconnecting a component from the refrigerant system, seal the open fittings with a cap or plug. This will prevent contamination from entering the A/C system. CAUTION: Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open a container of refrigerant oil until you are ready to use it. Replace the cap on the oil container immediately after using. Store refrigerant oil only in a clean, airtight, and moisture-free container. CAUTION: Do not overcharge the refrigerant system. Overcharging will cause excessive compressor head pressure and can cause compressor noise and A/C system failure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line Hose/Line HVAC: Description and Operation A/C Discharge Line DESCRIPTION The A/C discharge line is the refrigerant line that goes from the A/C compressor to the A/C condenser and has an integral fitting for the A/C pressure transducer. The A/C discharge line is made from light-weight aluminum tubing with braze-less and crimp type fittings and nylon tubes with rubber barrier hose. The A/C discharge line for the 5.9L and 6.7L diesel engines is serviced as an assembly with the A/C suction line. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C discharge line has no serviceable parts except the O-ring seals and gaskets. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C discharge line is removed. The A/C discharge line cannot be repaired and must be replaced if found to be leaking or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line > Page 2708 Hose/Line HVAC: Description and Operation A/C Liquid Line DESCRIPTION The A/C liquid line is the refrigerant line that carries refrigerant from the A/C condenser to the A/C evaporator. The A/C liquid line consists of two separate lines that connect to each other using a spring-lock type refrigerant line coupler. The A/C liquid line is made from light-weight aluminum tubing with braze-less and crimp type fittings and nylon tubes with rubber barrier hose. NOTE: A/C orifice tube size is different between gasoline and diesel engines. Be sure to use the correct A/C liquid line when replacement of the A/C orifice tube is required. The front section of the A/C liquid line includes the high-side service port and the rear section of the A/C liquid line includes the A/C fixed orifice tube. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C liquid line has no serviceable parts except for the O-ring seals and gaskets, high-side service port valve, cap and secondary retaining clip. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C liquid line is removed. The A/C liquid line cannot be repaired and must be replaced if found to be leaking or damaged, or if the fixed orifice tube is inoperative. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line > Page 2709 Hose/Line HVAC: Description and Operation A/C Suction Line DESCRIPTION The A/C suction line is the refrigerant line that goes from the A/C evaporator to the A/C compressor. The A/C suction line is made from light-weight aluminum tubing with braze-less and crimp type fittings and nylon tubes with rubber barrier hose. The A/C suction line for the 5.9L and 6.7L diesel engines is serviced as an assembly with the A/C discharge line. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C suction line has no serviceable parts except for the O-ring seals and the secondary retaining clip. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C suction line is removed. The A/C suction line cannot be repaired and must be replaced if found to be leaking or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line > Page 2710 Hose/Line HVAC: Description and Operation Plumbing Description DESCRIPTION The A/C refrigerant lines and hoses are used to carry the refrigerant between the various A/C system components. The refrigerant lines and hoses for the R-134a A/C system consist of a barrier-hose design with a nylon tube sandwiched between rubber layers. The nylon tube helps to contain the R-134a refrigerant, which has a small molecular structure. The ends of the refrigerant lines are made from lightweight aluminum and braze-less fittings. Any kinks or sharp bends in the refrigerant lines and hoses will reduce the capacity of the entire A/C system and can reduce the flow of refrigerant within the system. Operation OPERATION High pressures are produced in the refrigerant system when the A/C compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible refrigerant hoses at least once a year to make sure they are in good condition. The refrigerant lines and hoses are coupled to other A/C system components with block-type fittings. An O-ring seal, or a flat steel gasket with an integral O-ring (dual plane seal), is used to mate the refrigerant line fittings with A/C system components to ensure the integrity of the refrigerant system. The refrigerant lines and hoses cannot be repaired and must be replaced if leaking or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge Hose/Line HVAC: Service and Repair Line-A/C Discharge Removal 5.9L/6.7L DIESEL ENGINES WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. NOTE: The A/C discharge line for the 5.9L and the 6.7L diesel engine is serviced as an assembly with the A/C suction line. 1. Disconnect and isolate the negative battery cables. 2. Recover the refrigerant from the refrigerant system. 3. Remove the air filter housing cover. 4. Remove the secondary retaining clip (7) from the spring-lock coupler (1) that secures the A/C suction line (6) to the A/C accumulator (5). 5. Using the proper A/C line disconnect tool, disconnect the A/C suction line from the A/C accumulator and remove and discard the O-ring seals. 6. Install plugs in, or tape over the opened suction line fitting and the accumulator tube. 7. Disconnect the wire harness connector (5) from the A/C pressure transducer (4). 8. Remove the nut (2) that secures the A/C suction and discharge line assembly (3) to the A/C condenser (1). 9. Disconnect the A/C discharge line from the A/C condenser and remove and discard the O-ring seal and gasket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 2713 10. Remove the bolt (7) that secures the A/C suction and discharge line assembly to the A/C compressor (6). 11. Disconnect the A/C suction and discharge line assembly from the A/C compressor and remove and discard the O-ring seals and gasket. 12. Remove the A/C suction and discharge line assembly from the engine compartment. 13. Install plugs in, or tape over the opened refrigerant line fittings and the condenser and compressor ports. 14. If necessary, remove the A/C pressure transducer from the A/C discharge line. Installation 5.9L/6.7L DIESEL ENGINES CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: The A/C discharge line for the 5.9L and the 6.7L diesel engine is serviced as an assembly with the A/C suction line. 1. If removed, install the A/C pressure transducer (4) onto the A/C suction and discharge line assembly (3). 2. Remove the tape or plugs from the opened refrigerant line fittings and the condenser and compressor ports. 3. Position the A/C suction and discharge line assembly into the engine compartment. 4. Lubricate new O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Connect the A/C suction and discharge line assembly to the A/C condenser (1). 6. Install the nut (2) that secures the A/C discharge line to the A/C condenser. Tighten the nut to 23 Nm (17 ft. lbs.). 7. Connect the A/C suction and discharge line assembly to the A/C compressor (6). 8. Install the bolt (7) that secures the A/C suction and discharge line assembly to the A/C compressor. Tighten the bolt to 23 Nm (17 ft. lbs.). 9. Connect the wire harness connector (5) to the A/C pressure transducer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 2714 10. Remove the tape or plugs from the opened accumulator tube. 11. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the accumulator tube fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 12. Connect the A/C suction line (6) to the spring-lock coupler (1) on the A/C accumulator (5) and install the secondary retaining clip (7). 13. Install the air filter housing cover. 14. Reconnect the negative battery cables. 15. Evacuate the refrigerant system. 16. Adjust the refrigerant oil level. 17. Charge the refrigerant system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 2715 Hose/Line HVAC: Service and Repair Line-A/C Liquid Removal 5.9L/6.7L DIESEL ENGINES WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. NOTE: The A/C liquid line is serviced in two sections. FRONT SECTION 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system. 3. Remove the passenger side battery. 4. Remove the air seal from the right end of the A/C condenser (5) to gain access to the refrigerant line fittings. 5. Remove the nut (2) that secures the front section of the A/C liquid line (1) to the A/C condenser (3). 6. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring and gasket. 7. Disengage the A/C liquid line (1) from the three body retaining clips (2 and 3) located at the right front corner of the engine compartment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 2716 8. Remove the secondary retaining clip (2) from the spring-lock coupler that secures the front section of the A/C liquid line (1) to the rear section of the liquid line (3). 9. Using the proper A/C line disconnect tool (Special Tool Kit 7193 or equivalent), disconnect the front section of the A/C liquid line from the rear section of the liquid line and remove and discard the O-ring seals. 10. Install plugs in, or tape over the opened ends of the A/C liquid lines and the condenser port. 11. Remove the front section of the A/C liquid line from the engine compartment. REAR SECTION 12. Disconnect and isolate the negative battery cable. 13. Recover the refrigerant from the refrigerant system. 14. Remove the passenger side battery. 15. Disengage the rear section of the A/C liquid line (2) from the body retaining clip (5). 16. Remove the secondary retaining clip (1) from the spring-lock coupler that secures the front section of the A/C liquid line (6) to the rear section of the A/C liquid line. 17. Using the proper A/C line disconnect tool (Special Tool Kit 7193 or equivalent), disconnect the front section of the A/C liquid line from the rear section of the liquid line and remove and discard the O-ring seals. 18. Remove the secondary retaining clip (3) from the spring-lock coupler that secures the rear section of the A/C liquid line to the evaporator tube (4). 19. Using the proper A/C line disconnect tool (Special Tool Kit 7193 or equivalent), disconnect the A/C liquid line from the evaporator tube and remove and discard the O-ring seals. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 2717 20. Install plugs in, or tape over the opened ends of the A/C liquid lines and the evaporator tube, 21. Remove the rear section of the A/C liquid line from the engine compartment. Installation 5.9L/6.7L DIESEL ENGINES CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: The A/C liquid line is serviced in two sections. FRONT SECTION 1. Position the front section of the A/C liquid line (1) into the engine compartment. 2. Remove the tape or plugs from the opened ends of the A/C liquid lines and the condenser port. 3. Lubricate new O-ring seals with clean refrigerant oil and install them onto the front liquid line spring-lock coupler fitting. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the front section of the A/C liquid line to the rear section of the liquid line (3). 5. Install the secondary retaining clip (2) onto the spring-lock coupler that secures the front section of the A/C liquid line onto the rear section of the liquid line. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 2718 6. Engage the A/C liquid line (1) into the three body retaining clips (2 and 3) located at the right front corner of the engine compartment. 7. Lubricate a new O-ring with clean refrigerant oil and install it and a new gasket onto the front liquid line fitting. Use only the specified O-ring seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 8. Connect the front section of the A/C liquid line (2) to the condenser port. 9. Install the nut (1) that secures the A/C liquid line to the A/C condenser (3). Tighten the nut to 23 Nm (17 ft. lbs.). 10. Position the air seal over the right end of the A/C condenser and install the air seal retainers. 11. Install the passenger side battery tray. 12. Reconnect the negative battery cable(s). 13. Evacuate the refrigerant system. 14. Adjust the refrigerant oil level. 15. Charge the refrigerant system. REAR SECTION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 2719 16. Position the rear section of the A/C liquid line (2) into the engine compartment. 17. Remove the tape or plugs from the opened ends of the A/C liquid lines and the evaporator tube (4). 18. Lubricate new O-ring seals with clean refrigerant oil and install them onto the rear liquid line spring-lock coupler fitting. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 19. Connect the rear section of the A/C liquid line to the evaporator tube. 20. Install the secondary retaining clip (3) onto the spring-lock coupler that secures the rear section of the A/C liquid line onto the evaporator tube. 21. Engage the A/C liquid line into the body retaining clip (5). 22. Lubricate new O-ring seals with clean refrigerant oil and install them onto the front liquid line spring-lock coupler fitting. Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 23. Connect the rear section of the A/C liquid line (6) to the front section of the liquid line. 24. Install the secondary retaining clip (1) onto the spring-lock coupler that secures the front section of the A/C liquid line to the rear section of the liquid line. 25. Install the passenger side battery tray. 26. Reconnect the negative battery cables. 27. Evacuate the refrigerant system. 28. Adjust the refrigerant oil level. 29. Charge the refrigerant system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 2720 Hose/Line HVAC: Service and Repair Line-A/C Suction Removal 5.9L/6.7L DIESEL ENGINES WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. NOTE: The A/C suction line for the 5.9L and the 6.7L diesel engine is serviced as an assembly with the A/C discharge line. 1. Disconnect and isolate the negative battery cables. 2. Recover the refrigerant from the refrigerant system. 3. Remove the air filter housing cover. 4. Remove the secondary retaining clip (7) from the spring-lock coupler (1) that secures the A/C suction line (6) to the A/C accumulator (5). 5. Using the proper A/C line disconnect tool (Special Tool Kit 7193 or equivalent), disconnect the A/C suction line from the A/C accumulator and remove and discard the O-ring seals. 6. Install plugs in, or tape over the opened suction line fitting and the accumulator tube. 7. Disconnect the wire harness connector (5) from the A/C pressure transducer (4). 8. Remove the nut (2) that secures the A/C suction and discharge line assembly (3) to the A/C condenser (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 2721 9. Disconnect the A/C discharge line from the A/C condenser and remove and discard the O-ring seal and gasket. 10. Remove the bolt (7) that secures the A/C suction and discharge line assembly to the A/C compressor (6). 11. Disconnect the A/C suction and discharge line assembly from the A/C compressor and remove and discard the O-ring seals and gasket. 12. Remove the A/C suction and discharge line assembly from the engine compartment. 13. Install plugs in, or tape over the opened refrigerant line fittings and the condenser and compressor ports. 14. If necessary, remove the A/C pressure transducer from the A/C discharge line. Installation 5.9L/6.7L DIESEL ENGINES CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: The A/C suction line for the 5.9L and the 6.7L diesel engine is serviced as an assembly with the A/C discharge line. 1. If removed, install the A/C pressure transducer (4) onto the A/C suction and discharge line assembly (3). 2. Remove the tape or plugs from the opened refrigerant line fittings and the condenser and compressor ports. 3. Position the A/C suction and discharge line assembly into the engine compartment. 4. Lubricate new O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Connect the A/C suction and discharge line assembly to the A/C condenser (1). 6. Install the nut (2) that secures the A/C suction and discharge line assembly to the A/C condenser. Tighten the nut to 23 Nm (17 ft. lbs.). 7. Connect the A/C suction and discharge line assembly to the A/C compressor (6). 8. Install the bolt (7) that secures the A/C suction and discharge line assembly to the A/C compressor. Tighten the bolt to 23 Nm (17 ft. lbs.). 9. Connect the wire harness connector (5) to the A/C pressure transducer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 2722 10. Remove the tape or plugs from the opened accumulator tube. 11. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the accumulator tube fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 12. Connect the A/C suction line (6) to the spring-lock coupler (1) on the A/C accumulator (5) and install the secondary retaining clip (7). 13. Install the air filter housing cove. 14. Reconnect the negative battery cables. 15. Evacuate the refrigerant system. 16. Adjust the refrigerant oil level. 17. Charge the refrigerant system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hoses - I.F.S. Power Steering Line/Hose: Service and Repair Hoses - I.F.S. Return Hose - Gear To Cooler RETURN HOSE - GEAR TO COOLER 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the return hose at the cooler. 4. Disconnect the return hose (1) at the gear. 5. Remove the return hose from the routing clamp at the fan shroud and then remove from the vehicle. Pressure Hose PRESSURE HOSE 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the pressure hose at the pump. 4. Disconnect the pressure hose (2) at the gear. 5. Remove the pressure hose from the vehicle. Return Hose - Reservoir To Cooler RETURN HOSE - RESERVOIR TO COOLER 1. Drain and siphon the power steering system. 2. Disconnect the return hose at the reservoir. 3. Raise and support the vehicle. 4. Remove the return hose from the routing clamp at the fan shroud. 5. Disconnect the return hose at the cooler. 6. Remove the hose from the vehicle. Return Hose - Gear To Cooler Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hoses - I.F.S. > Page 2727 RETURN HOSE - GEAR TO COOLER 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reconnect the return hose (1) at the gear. Tighten the hose to 50 Nm (37 ft. lbs.). 4. Reattach the hose to the routing clip at the fan shroud. 5. Remove the support and lower the vehicle. 6. Refill the power steering system. Pressure Hose PRESSURE HOSE NOTE: Be sure to align the pressure hose so it does not contact the fan shroud or the frame rail. 1. Install the pressure hose to the vehicle. 2. Reconnect the pressure hose (2) at the gear. Tighten the hose to 32 Nm (23 ft. lbs.). 3. Reconnect the pressure hose at the pump. Tighten the hose to 31 Nm (23 ft. lbs.). 4. Remove the support and lower the vehicle. 5. Refill the power steering system. Return Hose - Reservoir To Cooler RETURN HOSE - RESERVOIR TO COOLER 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reattach the hose to the routing clip at the fan shroud. 4. Remove the support and lower the vehicle. 5. Reconnect the return hose at the reservoir. 6. Refill the power steering system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hoses - I.F.S. > Page 2728 Power Steering Line/Hose: Service and Repair Hoses - Link/Coil Return Hose - Gear To Cooler RETURN HOSE - GEAR TO COOLER 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the return hose at the cooler. 4. Disconnect the return hose (2) at the gear. 5. Remove the return hose from the routing clamp at the fan shroud and then remove from the vehicle. Pressure Hose PRESSURE HOSE 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the pressure hose at the pump. 4. Disconnect the pressure hose (2) at the gear (4). 5. Remove the pressure hose from the vehicle. Return Hose - Reservoir To Cooler RETURN HOSE - RESERVOIR TO COOLER 1. Drain and siphon the power steering system. 2. Disconnect the return hose at the reservoir. 3. Raise and support the vehicle. 4. Remove the return hose from the routing clamp at the fan shroud. 5. Disconnect the return hose at the cooler. 6. Remove the hose from the vehicle. Return Hose - Gear To Cooler Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hoses - I.F.S. > Page 2729 RETURN HOSE - GEAR TO COOLER 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reconnect the return hose (2) at the gear. Tighten the hose to 51 Nm (38 ft. lbs.). 4. Reattach the hose to the routing clip at the fan shroud. 5. Remove the support and lower the vehicle. 6. Refill the power steering system. Pressure Hose PRESSURE HOSE NOTE: Be sure to align the pressure hose so it does not contact the fan shroud or the frame rail. 1. Install the pressure hose to the vehicle. 2. Reconnect the pressure hose (2) at the gear (4). Tighten the hose to 32 Nm (23 ft. lbs.). 3. Reconnect the pressure hose at the pump. Tighten the hose to 36 Nm (27 ft. lbs.). 4. Remove the support and lower the vehicle. 5. Refill the power steering system. Return Hose - Reservoir To Cooler RETURN HOSE - RESERVOIR TO COOLER 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reattach the hose to the routing clip at the fan shroud. 4. Remove the support and lower the vehicle. 5. Reconnect the return hose at the reservoir. 6. Refill the power steering system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Brake Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2735 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 2736 Brake Fluid: Specifications BRAKE FLUID Mopar DOT 3 and SAE J1703 or equivalent. NOTE: If DOT 3 is not available, the DOT 4 is acceptable. Use only recommended brake fluids. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 2737 Brake Fluid: Description and Operation BRAKE FLUID The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum-based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 2738 Brake Fluid: Testing and Inspection BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If brake fluid is contaminated, drain and thoroughly flush system. Replace master cylinder, proportioning valve, caliper seals, wheel cylinder seals, Antilock Brakes hydraulic unit and all hydraulic fluid hoses. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 2739 Brake Fluid: Service and Repair BRAKE FLUID LEVEL Always clean the master cylinder reservoir (1) and cap (2) before checking fluid level. If not cleaned, dirt could enter the fluid. The fluid fill level is indicated on the side of the master cylinder reservoir (1). The correct fluid level is to the MAX indicator on the side of the reservoir. If necessary, add fluid to the proper level. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Clutch Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2744 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Coolant: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2749 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications ENGINE COOLANT Capacity ............................................................................................................................................... ...................................... * 21.4 liters (22.6 quarts) * Includes 0.9 liters (1.0 quarts) for coolant reservoir. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 2752 Coolant: Fluid Type Specifications ENGINE COOLANT Mopar Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Organic Additive Technology) or equivalent. NOTE: 50/50 Ethylene-Glycol and Distilled Water is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation. maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67°C (-90° F). A higher percentage will freeze in warmer temperature. Also a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. NOTE: This coolant offers the best engine cooling without corrosion when mixed with 50% Ethylene-Glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it looses color or becomes contaminated, drain, flush and replace with fresh properly mixed coolant solution. CAUTION: Do not use coolant additives that are claimed to improve cooling. CAUTION: Mopar Antifreeze/Coolant, 5 year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified non-HOAT or other HOAT coolant, may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Description Coolant: Description and Operation Description Coolant COOLANT WARNING: Antifreeze is an ethylene glycol base coolant and is harmful if swallowed or inhaled. If swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area. Seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene glycol. Keep out of reach of children. Dispose of glycol base coolant properly, contact your dealer or government agency for location of collection center in your area. Do not open a cooling system when the engine is at operating temperature or hot under pressure, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. ETHYLENE-GLYCOL MIXTURES CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar(R) Antifreeze/Coolant, 5 Year 100,000 Mile Formula (ethylene-glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain a freeze point of -37°C (-35°F). The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower than 44 percent, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68% antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22°C (-8°F). PROPYLENE-GLYCOL MIXTURES It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32°C (-26°F). 5° C higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of propylene-glycol is 125°C (257°F) at 96.5 kPa (14 psi), compared to 128°C (263°F) for ethylene-glycol. Use of propylene-glycol can result in boil-over or freeze-up on a cooling system designed for ethylene-glycol. Propylene- glycol also has poorer heat transfer characteristics than ethylene-glycol. This can increase cylinder head temperatures under certain conditions. Propylene-glycol/ethylene-glycol Mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the various cooling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining freeze point will not be accurate. Both the refractive index and specific gravity differ between ethylene glycol and propylene-glycol. HOAT Coolant HOAT COOLANT WARNING: Antifreeze is an ethylene-glycol base coolant and is harmful if swallowed or inhaled. If swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area. Seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene-glycol. Keep out of reach of children. Dispose of glycol base coolant properly, contact your dealer or government agency for location of collection center in your area. Do not open a cooling system when the engine is at operating temperature or hot under pressure, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene-glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Description > Page 2755 Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. COOLANT PERFORMANCE The required ethylene-glycol and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows: Pure Water- Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F). 50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. COOLANT SELECTION AND ADDITIVES The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain a freeze point of -37 °C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Do not use coolant additives that are claimed to improve engine cooling. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Description > Page 2756 Coolant: Description and Operation Operation OPERATION Coolant flows through the engine block, cylinder head, absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere. On the 6.7L diesel engine, coolant also flows through the EGR cooler and turbocharger actuator. During cold weather the ethylene-glycol or propylene-glycol coolant prevents water present in the cooling system from freezing within temperatures indicated by mixture ratio of coolant to water. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Page 2757 Coolant: Testing and Inspection COOLANT CONCENTRATION TESTING Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37°C (-34°F) to -46°C (-50°F). The use of a hydrometer or Tool 8266, refractometer can be used to test coolant concentration. A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and higher the freeze protection (up to a maximum of 60% by volume glycol). A Refractometer Tool 8286 will test the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufactures use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and is not recommended. CAUTION: Do not mix types of coolant - corrosion protection will be severely reduced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2762 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2767 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2772 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2777 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2782 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2783 Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2784 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2785 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2786 Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2787 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2788 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Service Fill 42RLE .................................................................................................................................................. ...................................................... 3.8Liters (4.0 Qt) 45RFE/545RFE 4X2 ............................................................................................................................ ................................................................................. 5.2Liters (5.5 Qt) 4X4 ........................................ .............................................................................................................................................................. ....... 6.2Liters (6.5 Qt) 48RE .................................................................................................................................................... ....................................................... 3.8Liters (4.0 Qt) 68RFE 4X2 .......................................................................................................................................... ................................................................... 5.2Liters (5.5 Qt) 4X4 ...................................................... ....................................................................................................................................................... 6.2Liters (6.5 Qt) AS68RC ............................................................................................................................................... ...................................................... 6.8Liters (7.2 Qt) Overhaul * 42RLE .................................................................................................................................................. ...................................................... 8.3Liters (8.7 Qt) 45RFE/545RFE ................................................................................................................................... ........................................ 14-16Liters (14.8-16.9 Qt) 48RE .................................................................................................................................................... ........................................ 14-16Liters (14.8-16.9 Qt) 68RFE ................................................................................................................................................. ................................... 15.6-16.6Liters (16.4-17.5 Qt) AS68RC ............................................................................................................................................... ................................................ 13.0Liters (13.74 Qt) *Dry fill capacity. Depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler, these figures may vary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 2791 Fluid - A/T: Fluid Type Specifications AUTOMATIC TRANSMISSION FLUID (All but AISIN Transmission) Mopar ATF +4 Automatic Transmission Fluid AISIN TRANSMISSION Mopar AS68RC Automatic Transmission Fluid Dexron II fluid IS NOT recommended. Clutch chatter can result from the use of improper fluid. NOTE: Mopar ATF +4 and AS68RC, Automatic Transmission Fluids when new are red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF +4 and AS68RC, also have a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. DaimlerChrysler strongly recommends against the addition of any fluids to the transmission, other than those automatic transmission fluids listed above. Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks. Various "special" additives and supplements exist that claim to improve shift feel and/or quality. These additives and others also claim to improve converter clutch operation and inhibit overheating, oxidation, varnish and sludge. These claims have not been supported to the satisfaction of DaimlerChrysler and these additives must not be used. The use of transmission "sealers" should also be avoided, since they may adversely affect the integrity of transmission seals. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > 68RFE Automatic Transmission Fluid - A/T: Testing and Inspection 68RFE Automatic Transmission Effects Of Incorrect Fluid Level EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Causes Of Burnt Fluid CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. 1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. 2. A result of restricted fluid flow through the main and auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged oil cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Fluid Contamination FLUID CONTAMINATION Transmission fluid contamination is generally a result of: - adding incorrect fluid - failure to clean dipstick and fill tube when checking level - engine coolant entering the fluid - internal failure that generates debris - overheat that generates sludge (fluid breakdown) - failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > 68RFE Automatic Transmission > Page 2794 Fluid - A/T: Testing and Inspection 48RE Automatic Transmission Effects Of Incorrect Fluid Level EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Causes Of Burnt Fluid CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has two primary causes. 1. A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged oil cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 2. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Fluid Contamination FLUID CONTAMINATION Transmission fluid contamination is generally a result of: - adding incorrect fluid - failure to clean dipstick and fill tube when checking level - engine coolant entering the fluid - internal failure that generates debris - overheat that generates sludge (fluid breakdown) - failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > 68RFE Automatic Transmission > Page 2795 Fluid - A/T: Testing and Inspection AS68RC Automatic Transmission Effects Of Incorrect Fluid Level EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Causes Of Burnt Fluid CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. 1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. 2. A result of restricted fluid flow through the main and/or auxiliary cooler. 3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Fluid Contamination FLUID CONTAMINATION Transmission fluid contamination is generally a result of: - adding incorrect fluid. - failure to clean dipstick and fill tube when checking level. - engine coolant entering the fluid. - internal failure that generates debris. - overheat that generates sludge (fluid breakdown). - failure to replace contaminated converter after repair. The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The torque converter should be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Fluid - A/T: Service and Repair 68RFE Automatic Transmission Fluid Level Check FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmssion has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P (PARK) and N (NEUTRAL) positions. Place the selector lever in P (PARK) to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82° C. or 180° F), the fluid level is correct if it is in the HOT region (cross-hatched area) on the oil level indicator. The fluid level will be approximately at the upper COLD hole of the dipstick at 21° C (70° F) fluid temperature. FILL TUBE EQUIPPED WITH INDICATOR NOTE: Engine and Transmission should be at normal operating temperature before performing this procedure. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Hook up scan tool and select transmission. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the Transmission Fluid Temperature Chart. NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2798 transmission before rechecking the fluid level. 10. Check transmission for leaks. CAPPED FILL TUBE 1. Verify that the vehicle is parked on a level surface. 2. Remove the dipstick tube cap. WARNING: There is a risk of accident from vehicle starting off by itself when engine is running. There is a risk of injury from contusions and burns if you insert your hands into the engine when it is started or when it is running. Secure vehicle to prevent it from moving off by itself. Wear properly fastened and close-fitting work clothes. Do not touch hot or rotating parts. 3. Actuate the service brake. Start engine and let it run at idle speed in selector lever position "P". 4. Shift through the transmission modes several times with the vehicle stationary and the engine idling. 5. Warm up the transmission, wait at least 2 minutes and check the oil level with the engine running. Push the Oil Dipstick 9336 into transmission fill tube until the dipstick tip contacts the oil pan and pull out again, read off oil level, repeat if necessary. NOTE: The dipstick will protrude from the fill tube when installed. 6. Check transmission oil temperature using the appropriate scan tool. NOTE: The true transmission oil temperature can only be read by a scan tool in REVERSE or any forward gear position. 7. The transmission Oil Dipstick 9336 has indicator marks every 10 mm. Determine the height of the oil level on the dipstick and using the height, the transmission temperature, and the Transmission Fluid Graph, determine if the transmission oil level is correct. 8. Add or remove oil as necessary and recheck the oil level. 9. Once the oil level is correct, install the dipstick tube cap. Fluid And Filter Replacement FLUID AND FILTER REPLACEMENT REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2799 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. Transmission Filters - 4X4 Shown 9. Remove the screw holding the primary oil filter (1) to valve body. 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Inspect the oil filter seal in the bottom of the oil pump. If the seal is not installed completely in the oil pump, or is otherwise damaged, then remove and discard the oil filter seal from the bottom of the oil pump. If the seal is installed correctly and is in good condition, it can be reused. 12. If replacing the cooler return filter (2), use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the diagnosis information. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2800 Transmission Filters - 4X4 Shown CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 1. If necessary, install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with Installer 6960-A or another suitable tool (appropriately sized drift or socket, the butt end of a hammer etc.). 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold the primary oil filter (1) to valve body. Tighten screw to 4.5 Nm (40 in. lbs.) torque. 4. Install new cooler return filter (2) onto the transmission, if necessary. Torque the filter to 9.5 Nm (84 in.lbs.). 5. Place bead of Mopar(R) RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 12 Nm (105 in. lbs.) torque. 8. Lower vehicle and fill transmission with MOPAR(R) ATF +4. Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar(R) ATF +4 to transmission: a. If only fluid and filter were changed, add 10 pints (5 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled and the torque converter was replaced or drained, add 24 pints (12 quarts) of ATF +4 to transmission. 3. Check the transmission fluid, refer to FLUID - STANDARD PROCEDURE and adjust as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2801 Fluid - A/T: Service and Repair 48RE Automatic Transmission Fluid Level Check FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmssion has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. The transmission fluid level can be checked two ways. PROCEDURE ONE 1. Transmission fluid must be at normal operating temperature for accurate fluid level check. Drive vehicle if necessary to bring fluid temperature up to normal hot operating temperature of 82°C (180°F). 2. Position vehicle on level surface. 3. Start and run engine at curb idle speed. 4. Apply parking brakes. 5. Shift transmission momentarily into all gear ranges. Then shift transmission back to NEUTRAL. 6. Clean top of filler tube and dipstick to keep dirt from entering tube. 7. Remove dipstick (1) and check fluid level as follows: a. Correct acceptable level is in crosshatch area. b. Correct maximum level is to MAX arrow mark. c. Incorrect level is at or below MIN line. d. If fluid is low, add only enough Mopar(R) ATF +4 to restore correct level. Do not overfill. PROCEDURE TWO Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2802 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into NEUTRAL. 5. Hook up scan tool and select engine. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the chart. NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Fluid And Filter Replacement FLUID AND FILTER REPLACEMENT The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan (3). 3. Remove bolts holding front and sides of pan to transmission (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2803 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan and reusable gasket (2) away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolt holding pan to transmission. 7. While holding pan level, lower pan and gasket away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screws holding filter (2) to valve body. 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used trans fluid and filter properly. INSTALLATION 1. Position a new transmission oil filter (2) onto the valve body. 2. Install the screws to hold the filter to the valve body. Tighten the screws to 4 Nm (35 in.lbs.). 3. Clean the gasket surfaces of the transmission oil pan (3) and transmission pan rail. NOTE: The transmission pan oil gasket (2) is reusable. Inspect the sealing surfaces of the gasket. If the sealing ribs on both surfaces Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2804 appear to be in good condition, clean the gasket of any foreign material and reinstall. 4. Position the oil pan gasket (2) onto the oil pan (3). 5. Position the oil pan and gasket onto the transmission and install several bolts to hold the pan and gasket to the transmission. 6. Install the remainder of the oil pan bolts. Tighten the bolts to 13.6 Nm (125 in.lbs.). 7. Lower vehicle and fill transmission. Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar(R) ATF +4 to transmission: a. If only fluid and filter were changed, add 3 pints (1-1/2 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, torque converter was replaced or drained, and cooler was flushed, add 12 pints (6 quarts) of ATF +4 to transmission. 3. Apply parking brakes. 4. Start and run engine at normal curb idle speed. 5. Apply service brakes, shift transmission through all gear ranges then back to NEUTRAL, set parking brake, and leave engine running at curb idle speed. 6. Remove funnel, insert dipstick and check fluid level. If level is low, add fluid to bring level to MIN mark on dipstick. Check to see if the oil level is equal on both sides of the dipstick. If one side is noticeably higher than the other, the dipstick has picked up some oil from the dipstick tube. Allow the oil to drain down the dipstick tube and re-check. 7. Drive vehicle until transmission fluid is at normal operating temperature. 8. With the engine running at curb idle speed, the gear selector in NEUTRAL, and the parking brake applied, check the transmission fluid level. CAUTION: Do not overfill transmission, fluid foaming and shifting problems can result. 9. Add fluid to bring level up to MAX arrow mark. When fluid level is correct, shut engine off, release park brake, remove funnel, and install dipstick in fill tube. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2805 Fluid - A/T: Service and Repair AS68RC Automatic Transmission Fluid Level Check FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmission has too much fluid, the gear train churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P (PARK) and N (NEUTRAL) positions. Place the selector lever in P (PARK) to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82° C. or 180° F), the fluid level is correct if it is in the HOT region (cross-hatched area) on the oil level indicator. The fluid level will be approximately at the upper COLD hole of the dipstick at 21° C (70° F) fluid temperature. NOTE: Engine and Transmission should be at normal operating temperature before performing this procedure. Optimum fluid temperature for checking the level should be between 70°C (158°F) and 80°C ( 176°F). 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Connect the scan tool and select transmission. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the Transmission Fluid Temperature Chart. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2806 NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Fluid And Filter Replacement FLUID AND FILTER REPLACEMENT REMOVAL DRAIN PLUG 1. Raise vehicle. 2. Place a large diameter drain pan beneath the transmission pan. 3. Remove the drain plug bolt (1) and allow the oil to drain from the transmission pan. 4. Remove the drain pan bolts from the transmission case. 5. Remove the drain pan. TRANSMISSION OIL FILTER Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2807 6. Remove the transmission oil filter bolts (3). 7. Remove the transmission oil filter and O-ring seal from the valve body (1). INSPECTION OIL PAN MAGNETS Inspect bottom of pan, pick-up magnets (1) and magnetic drain plug (2) and fluid filter for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the diagnosis information. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2808 TRANSMISSION OIL FILTER 1. Lubricate the transmission oil filter seal with MOPAR(R) AS68RC ATF. 2. Install the new transmission oil filter (2) in position on valve body (1) and into the oil pump. 3. Install the transmission oil filter bolts (3). 4. Tighten bolts to 10 Nm ( 88 in.lbs. ) torque. 5. Install a new transmission oil pan gasket. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 7 Nm (62 in. lbs.) torque. DRAIN PLUG 8. Install transmission drain plug bolt (1). 9. Tighten oil pan drain plug to 27 Nm ( 20 ft.lbs) torque. 10. Lower vehicle and fill transmission with MOPAR(R) AS68RC ATF. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2809 Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar(R) AS68RC ATF to transmission: a. If only fluid and filter were changed, add 6.8L (7.2 quarts) of AS68RC to transmission. b. If transmission was completely overhauled and the torque converter was replaced or drained, add 13L (13.75 quarts) of Mopar(R) AS68RC ATF to transmission. 3. Check the transmission fluid and adjust as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2814 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2819 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications MANUAL TRANSMISSION FLUID CAPACITY Diesel Engine - G56 ............................................................................................................................ .............................................................. 5.6 L (3.4 Pt) 5.7 L Engine - G56 .............................................................................................................................. .............................................................. 4.7 L (10 Pt) Getrag 238 ........................................................................................................................................... ............................................................. 2.2 L (4.6 Pt) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 2822 Fluid - M/T: Fluid Type Specifications NOTE: DaimlerChrysler recommends using Mopar lubricants or lubricants of equal quality. MANUAL TRANSMISSION LUBRICANT G56 ...................................................................................................................................................... ........................... Mopar ATF +4 Transmission Fluid Getrag 238 ....................................................... ............................................................................................................... Mopar ATF +4 Transmission Fluid Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Differential: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2827 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2828 Fluid - Differential: Technical Service Bulletins Differential - Fluid Level Inspection Procedure NUMBER: 03-003-06 GROUP: Axle DATE: October 20, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 03-001-04 REV. A, DATED MAY 11, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS. SUBJECT: Axle Fluid Level MODELS: 2004 (AN) Dakota **2004 - 2007** (DR/DH/D1/DC) Ram Truck **2004 - 2007** (HB/HG) Durango / Aspen **2005 - 2007** (ND) Dakota DISCUSSION: The axle fill holes on some Dodge Truck vehicle axles may be located considerably higher than the actual fluid level. Filling the axle until the fluid comes out of the fill hole will over fill the axle, which may cause fluid foaming. When checking fluid level or filling a rear axle with fluid, you must measure the distance from the bottom of the fill hole to the top of the actual fluid level. This can easily be accomplished using a pipe cleaner or piece of wire. Make a 90 degree bend in the wire 2 inches from the end. The wire can then be inserted into the axle fill hole to use as a dipstick. Measure the distance from the bend to the oil level. The fluid levels for the axles are shown in the table below. CORRECT FLUID LEVELS FOR DURANGO / ASPEN: NOTE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2829 The Trac-Lok feature is not available on Durango rear axles. Traction control is provided electronically through the ABS system. Trac-Lok additives or friction modifiers are not required. CORRECT FLUID LEVELS FOR RAM TRUCK 1500: CORRECT FLUID LEVELS FOR RAM TRUCK 2500 -3500: CORRECT FLUID LEVELS FOR DAKOTA: NOTE: The Trac-Lok feature is available on Dakota rear axles. Trac-Lok additives are required on axles equipped with Trac Lok. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications FRONT AXLE CAPACITY ± .03 L (1 oz.) C205FD ............................................................................................................................................... ............................................................. 1.6 L (56 oz.) 9 1/4 AA ........................................................... ................................................................................................................................................ 2.5 L (74 oz.) 9 1/4 AA EL ............................................................................................................................ ......................................................................... 2.0 L (68 oz.) REAR AXLE CAPACITY ± .03 L (1 oz.) 9 1/4 ..................................................................................................................................................... .......................................................... * 2.1 L (72 oz.) 10 1/2 AA ......................................................... ................................................................................................................................................ 2.5 L (85 oz.) 10 1/2 AA EL .......................................................................................................................... ......................................................................... 2.5 L (85 oz.) 11 1/2 AA open .................................... .......................................................................................................................................................... 4.2 L (142 oz.) 11 1/2 AA Trac-Rite ..................................................................................................... .................................................................................. 4.0 L (135 oz.) *With Trac-Lok add 118 ml (4 oz.) of Limited Slip Additive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 2832 Fluid - Differential: Fluid Type Specifications NOTE: DaimlerChrysler recommends using Mopar lubricants or lubricants of equal quality. FRONT AXLE LUBRICANT C205FD ............................................................................................................................................... ................. Mopar Synthetic Gear Lubricant 75W-90 9 1/4 AA ........................................................... .................................................................................................... Mopar Synthetic Gear Lubricant 75W-90 9 1/4 AA EL ......................................................................................................................................................... Mopar Synthetic Gear Lubricant 75W-90 REAR AXLE LUBRICANT 9 1/4 ..................................................................................................................................................... ............... Mopar Synthetic Gear Lubricant 75W-140 10 1/2 AA ............................................................................................................................................................. Mopar Synthetic Gear Lubricant 75W-90 10 1/2 AA EL ...................................................................................................................................................... Mopar Synthetic Gear Lubricant 75W-90 11 1/2 AA ............................................................................................................................................................ Mopar Synthetic Gear Lubricant 75W-90 NOTE: Trac-Lok differentials require Limited Slip Additive in the lubricant. Trac-Rite/Trac-Rite EL differentials DO NOT require Limited Slip Additive. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2837 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications TRANSFER CASE FLUID CAPACITY NV241 GENII ....................................................................................................................................... ........................................................... 1.6 L (3.4 Pt) NV243 ................................................................ .............................................................................................................................................. 1.6 L (3.4 Pt) NV244 GENII .......................................................................................................................... ........................................................................ 1.6 L (3.4 Pt) NV 246 .................................................. ........................................................................................................................................................... 1.9 L (4.0 Pt) NV271 ............................................................................................................................ ................................................................................ 1.89 L (4.0 Pt) NV273 ......................................... .............................................................................................................................................................. ..... 1.89 L (4.0 Pt) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 2840 Fluid - Transfer Case: Fluid Type Specifications TRANSFER CASE LUBRICANT All except NV246 ......................................................................................................................................... Mopar ATF +4 Automatic Transmission Fluid NV246 ....................................................................................................................................................... Mopar NVG246 Automatic Transmission Fluid Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case Fluid - Transfer Case: Service and Repair NV241 GENII Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 2843 Fluid - Transfer Case: Service and Repair NV271 Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (1) and drain (2) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 2844 Fluid - Transfer Case: Service and Repair NV243 Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 2845 Fluid - Transfer Case: Service and Repair NV244 GENII Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL NOTE: The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain (3) and fill (2) plugs and drain lubricant completely. 4. Install drain plug (3). Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug (2) to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 2846 Fluid - Transfer Case: Service and Repair NV241 GENII Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. NV271 Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (1) and drain (2) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 2847 NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. NV243 Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. NV244 GENII Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 2848 NOTE: The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain (3) and fill (2) plugs and drain lubricant completely. 4. Install drain plug (3). Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug (2) to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. NV246 Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (2) and drain (1) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 27 Nm (20 ft. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 2849 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with the correct fluid for the application. 7. Install and tighten fill plug to 27 Nm (20 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. NV273 Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (1) and drain (2) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Engine Oil: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2854 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil with Filter ............................................................................................................................ ................................................. 11.4Liters (12.0 Qt) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2857 Engine Oil: Fluid Type Specifications ENGINE OIL ........................................................................................................................................ ........................................................ Mopar 15W-40 Low ash diesel engine oil is REQUIRED for the 6.7L engine. NOTE: Use only Low Ash Diesel Engine Oil meeting standard MIL-2104C or API Classification CJ or higher that meets CES 20081 Standards. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 2858 Engine Oil: Testing and Inspection ENGINE OIL LEVEL CAUTION: Do not overfill crankcase with engine oil, oil foaming and oil pressure loss can result. To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable oil level is in the SAFE RANGE (3) on the engine oil dipstick. NOTE: The best time to check the engine oil level is after the engine is at operating temperature and has been turned off (not running) for 30 minutes. 1. Position vehicle on level surface. 2. With engine OFF, allow approximately 30 minutes for oil to settle to bottom of crankcase, remove engine oil dipstick. 3. Wipe dipstick clean. 4. Replace dipstick and verify it is seated in the tube. 5. Remove dipstick, with handle held above the tip, take oil level reading. 6. Add oil only if level is below the SAFE RANGE area on the dipstick. 7. Replace dipstick. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 2859 Engine Oil: Service and Repair ENGINE OIL SERVICE WARNING: Hot oil can cause personal injury. NOTE: Change engine oil and filter at intervals specified in the owner's manual. 1. Operate the engine until the water temperature reaches 60°C (140°F). Shut the engine off. 2. Use a container that can hold at least 14 liters (15 quarts) to hold the used oil. Remove the oil drain plug and drain the used engine oil into the container. 3. Always check the condition of the used oil. This can give you an indication of engine problems that might exist. - Thin, black oil indicates fuel dilution. - Milky discoloration indicates coolant dilution. 4. Clean the area around the oil filter head. Remove the filter. 5. Install new oil filter. 6. Clean the drain plug and the sealing surface of the pan. Check the condition of the threads and sealing surface on the oil pan and drain plug. 7. Install the drain plug. Tighten the plug to 50 Nm (37 ft. lbs.) torque. 8. Use only High-Quality Low Ash Multi-Viscosity lubricating oil in the Cummins Turbo Diesel engine. 9. Fill the engine with the correct grade of new oil. 10. Start the engine and operate it at idle for several minutes. Check for leaks at the filter and drain plug. 11. Stop engine. Wait 30 minutes to allow the oil to drain back to the pan and check the level again. USED ENGINE OIL DISPOSAL Care should be exercised when disposing of used engine oil after it has been drained from a vehicle's engine. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Power Steering Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2864 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 2865 Power Steering Fluid: Specifications POWER STEERING FLUID Mopar ATF +4 Automatic Transmission Fluid. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 2866 Power Steering Fluid: Description and Operation DESCRIPTION NOTE: It is normal that some pressure will build up inside the reservoir, especially, with a warm vehicle. A slight popping noise upon removal of the cap is normal. The fluid level should read between the ADD and the FULL COLD marks. When the fluid is hot it should read between ADD and FULL HOT marks. Only add fluid when the vehicle is cold. The recommended fluid for the power steering system is Mopar(R) ATF +4. Mopar(R) ATF+4, when new is red in color. The ATF+4 is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition, As the vehicle is driven, the ATF+4 will begin to look darker in color and may eventually become brown. THIS IS NORMAL. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 2867 Power Steering Fluid: Testing and Inspection POWER STEERING FLUID LEVEL CHECKING WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS. CAUTION: MOPAR(R) ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill. The power steering fluid level can be viewed on the dipstick attached to the filler cap. There are two ranges listed on the dipstick, COLD and HOT. Before opening power steering system, wipe the reservoir filler cap free of dirt and debris. Remove the cap and check the fluid level on its dipstick. When the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F), the fluid level should read between the minimum and maximum area of the cold range. When the fluid is hot, fluid level is allowed to read up to the highest end of the HOT range. Only add fluid when the vehicle is cold. Use only Mopar(R) ATF+4. Do not overfill the power steering system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 2868 Power Steering Fluid: Service and Repair POWER STEERING SYSTEM BLEEDING WARNING: The fluid level should be checked with engine off to prevent injury from moving components. CAUTION: Mopar(R) Power Steering Fluid + 4 or Mopar(R) ATF+4 Automatic Transmission Fluid is to be used in the power steering system. Both Fluids have the same material standard specifications (MS-9602). No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if another fluid is used. Do not overfill the system. CAUTION: If the air is not purged from the power steering system correctly, pump failure could result. NOTE: Be sure the vacuum tool used in the following procedure is clean and free of any fluids. 1. Check the fluid level. As measured on the side of the reservoir, the level should indicate between MAX and MIN when the fluid is at normal ambient temperature. Adjust the fluid level as necessary. 2. Tightly insert Power Steering Cap Adapter (4), Special Tool 9688, into the mouth of the reservoir (3). CAUTION: Failure to use a the vacuum pump reservoir (1) may allow power steering fluid to be sucked into the hand vacuum pump. 3. Attach Hand Vacuum Pump (2), Special Tool C-4207 or equivalent, with reservoir (1) attached, to the Power Steering Cap Adapter (4). CAUTION: Do not run the engine while vacuum is applied to the power steering system. Damage to the power steering pump can occur. NOTE: When performing the following step make sure the vacuum level is maintained during the entire time period. 4. Using Hand Vacuum Pump (2), apply 68-85 kPa (20-25 in. Hg) of vacuum to the system for a minimum of three minutes. 5. Slowly release the vacuum and remove the special tools. 6. Adjust the fluid level as necessary. Refer to STEP 1. 7. Repeat STEP 1 through STEP 6 until the fluid no longer drops when vacuum is applied. 8. Start the engine and cycle the steering wheel lock-to-lock three times. NOTE: Do not hold the steering wheel at the stops. 9. Stop the engine and check for leaks at all connections. 10. Check for any signs of air in the reservoir and check the fluid level. If air is present, repeat the procedure as necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications Refrigerant: Specifications R-134a Refrigerent Charge Capacity 1. 3.7/4.7/5.7 L ..................................................................................................................................... .......................................... 0.728 kg (1.604 lbs.) 2. 5.9/6.7 L .............................................................. ....................................................................................................................... 0.850 kg (1.873 lbs.) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Description and Operation > Description Refrigerant: Description and Operation Description DESCRIPTION The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a Chlorofluorocarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-flammable, clear, and colorless liquefied gas. Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Description and Operation > Description > Page 2874 Refrigerant: Description and Operation Operation OPERATION R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure, refrigerant oil sludge or poor A/C system performance. In addition, the polyalkylene glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a refrigerant system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the A/C compressor to identify that the A/C system is equipped with R-134a refrigerant. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Description and Operation > Page 2875 Refrigerant: Testing and Inspection REFRIGERANT SYSTEM LEAKS WARNING: R-134a service equipment or vehicle A/C system should not be pressure tested or leak tested with compressed air. Mixture of air and R-134a can be combustible at elevated pressures. These mixtures are potentially dangerous and may result in fire or explosion causing property damage and serious or fatal injury . Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Use only approved service equipment meeting SAE requirements to discharge an R-134a system. If accidental system discharge occurs, ventilate work area before resuming service. NOTE: If the A/C refrigerant system charge is empty or low, a leak in the A/C system is likely. Visually inspect all A/C lines, fittings and components for an oily residue. Oil residue can be an indicator of an A/C system leak location. NOTE: The only way to correctly determine if the refrigerant system is fully charged with R-134a is to completely evacuate and recharge the A/C system. Connect a suitable manifold gauge set and determine if the static A/C system pressure is above or below 345 kPa (50 psi). If less than 345 kPa (50 psi) , proceed to SYSTEM EMPTY. If greater than 345 kPa (50 psi), go to SYSTEM LOW. SYSTEM EMPTY 1. Evacuate the refrigerant system to the lowest degree of vacuum possible (approximately -88 kPa (- 26 in. Hg) or greater vacuum). Determine if the system holds a vacuum for 15 minutes. If vacuum is held, a leak is probably not present. If system will not maintain vacuum level, proceed to STEP 2. 2. Prepare and dispense 0.284 kilograms (10 ounces) of R-134a refrigerant into the evacuated refrigerant system and proceed to STEP 1 of the System Low procedure. SYSTEM LOW 3. Position the vehicle in a wind-free work area. This will aid in detecting small leaks. 4. Operate the heating-A/C system with the engine at idle under the following conditions for at least 5 minutes. - Doors or windows open - Transmission in Park or Neutral with the parking brake set (depending on application) - A/C-heater controls set to outside air, full cool, panel mode, high blower and with A/C compressor engaged CAUTION: A leak detector only designed for R-12 refrigerant will not detect leaks in an R-134a refrigerant system. 5. Shut the vehicle Off and wait 2-7 minutes. Then use an electronic leak detector that is designed to detect R-134a refrigerant and search for leaks. Fittings, lines or components that appear to be oily usually indicate a refrigerant leak. To inspect the A/C evaporator for leaks, insert the leak detector probe into the drain tube opening or an air outlet. A dye for R-134a is available to aid in leak detection. Use only DaimlerChrysler approved refrigerant dye. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery Refrigerant: Service and Repair Refrigerant System - Recovery REFRIGERANT SYSTEM RECOVERY WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions may result in serious or fatal injury. An R-134a refrigerant recovery/recycling/charging station (1) that meets SAE standard J2210 must be used to recover the refrigerant from the R-134a refrigerant system. Refer to the operating instructions supplied by the equipment manufacturer for the proper care and use of this equipment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery > Page 2878 Refrigerant: Service and Repair Refrigerant System - Evacuate REFRIGERANT SYSTEM EVACUATE NOTE: Special effort must be used to prevent moisture from entering the A/C system oil. Moisture in the oil is very difficult to remove and will cause a reliability problem with the A/C compressor. If an A/C compressor designed to use R-134a refrigerant is left open to the atmosphere for an extended period of time. It is recommended that the refrigerant oil be drained and replaced with new oil or a new A/C compressor be used. This will eliminate the possibility of contaminating the refrigerant system. If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be filled. Moisture and air mixed with the refrigerant will raise the compressor head pressure above acceptable operating levels. This will reduce the performance of the A/C system and damage the A/C compressor. Moisture will boil at near room temperature when exposed to vacuum. To evacuate the refrigerant system: NOTE: When connecting the service equipment coupling to the line fitting, verify that the valve of the coupling is fully closed. This will reduce the amount of effort required to make the connection. 1. Recover the refrigerant system. 2. Connect a suitable charging station, refrigerant recovery machine or a manifold gauge set with vacuum pump and refrigerant recovery equipment. 3. Open the suction and discharge valves and start the vacuum pump. The vacuum pump should run a minimum of 45 minutes prior to charge to eliminate all moisture in system. When the suction gauge reads to the lowest degree of vacuum possible (approximately -88 kPa (- 26 in. Hg) or greater) for 30 minutes, close all valves and turn off vacuum pump. If the system fails to reach specified vacuum, the refrigerant system likely has a leak that must be corrected. If the refrigerant system maintains specified vacuum for at least 30 minutes, start the vacuum pump, open the suction and discharge valves. Then allow the system to evacuate an additional 10 minutes. 4. Close all valves. Turn off and disconnect the vacuum pump. 5. Charge the refrigerant system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery > Page 2879 Refrigerant: Service and Repair Refrigerant System - Charge REFRIGERANT SYSTEM CHARGE WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions may result in serious or fatal injury. NOTE: The Underhood HVAC Specification Label contains the refrigerant fill specification of the vehicle being serviced. After all refrigerant system leaks have been repaired and the refrigerant system has been evacuated, a refrigerant charge can be injected into the system. An R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to charge the refrigerant system with R-134a refrigerant. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. CHARGING PROCEDURE CAUTION: A small amount of refrigerant oil is removed from the A/C system each time the refrigerant system is recovered and evacuated. Before charging the A/C system, you MUST replenish any oil lost during the recovery process. 1. Evacuate the refrigerant system. 2. Connect an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2210 to the refrigerant system. 3. Refer to A/C SPECIFICATIONS or the Underhood HVAC Specification Label for the proper amount of the refrigerant charge. 4. Measure the proper amount of refrigerant and heat it to 52° C (125° F) with the charging station. See the operating instructions supplied by the equipment manufacturer for proper use of this equipment. 5. Open both the suction and discharge valves, then open the charge valve to allow the heated refrigerant to flow into the system. 6. When the transfer of refrigerant has stopped, close both the suction and discharge valves. 7. If all of the refrigerant charge did not transfer from the dispensing device, open all of the windows in the vehicle and set the heating-A/C system controls so that the A/C compressor is engaged and the blower motor is operating at its lowest speed setting. Run the engine at a steady high idle ( about 1400 rpm). If the A/C compressor does not engage, test the compressor clutch circuits and repair as required. WARNING: Take care not to open the discharge (high pressure) valve at this time. Failure to follow this warning may result in serious or fatal injury. 8. Open the low-side valve to allow the remaining refrigerant to transfer to the refrigerant system. 9. Disconnect the charging station from the refrigerant system service ports. 10. Reinstall the caps onto the refrigerant system service ports. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Page 2880 Refrigerant: Tools and Equipment REFRIGERANT SYSTEM SERVICE EQUIPMENT WARNING: Eye protection must be worn when servicing an A/C refrigerant system. Turn all valves off (rotate clockwise) on the equipment being used before connecting or disconnecting service equipment from the refrigerant system. Failure to observe these warnings may result in personal injury or death. WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. When servicing the A/C system, an R-134a refrigerant recovery/recycling/charging station (1) that meets SAE standard J2210 must be used. Contact an automotive service equipment supplier for refrigerant recovery/recycling/charging equipment. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. A manifold gauge set (1) may be needed with some recovery/recycling/charging equipment. The manifold gauge set should have manual shut-off valves (2 and 6), or automatic back-flow valves located at the service port connector end of the manifold gauge set hoses (4 and 5). This will prevent refrigerant from being released into the atmosphere. MANIFOLD GAUGE SET CONNECTIONS CAUTION: Do not use an R-12 manifold gauge set on an R-134a system. The refrigerants are not compatible and system damage will result. RECOVERY/RECYCLING/EVACUATION/CHARGING HOSE- The center manifold hose (Yellow, or White, with Black stripe) (3) is used to Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Page 2881 recover, evacuate, and charge the refrigerant system. When the low or high pressure valves on the manifold gauge set are opened, the refrigerant in the system will escape through this hose. HIGH PRESSURE GAUGE HOSE- The high pressure hose (Red with Black stripe) (4) attaches to the high side service port. This service port is located on the A/C discharge line. On this model, an A/C pressure transducer is installed on the high side service port. A/C high-side pressures can be read using a scan tool. LOW PRESSURE GAUGE HOSE- The low pressure hose (Blue with Black stripe) (5) attaches to the low side service port. This service port is located either on the top of the A/C accumulator or on the A/C suction line near the accumulator, depending on engine application. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Description and Operation > Description Refrigerant Oil: Description and Operation Description DESCRIPTION The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, polyalkylene glycol (PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils, and should never be introduced to an R-134a refrigerant system. There are different PAG oils available, and each contains a different additive package. Use only refrigerant oil of the same type as recommended to service the refrigerant system (always refer to the specification tag included with the replacement A/C compressor or the A/C Underhood Specification Label located in the engine compartment). The Denso 10S17 A/C compressor used in this vehicle when equipped with the 3.7L, 4.7L or 5.7L engine is designed to use ND-8 PAG refrigerant oil. Use only this type of refrigerant oil when servicing the A/C compressor for these engines. The Visteon HS-18 A/C compressor used in this vehicle when equipped with 5.9L or 6.7L diesel engine is designed to use VC-46 PAG refrigerant oil. Use only this type of refrigerant oil when servicing this A/C compressor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Description and Operation > Description > Page 2887 Refrigerant Oil: Description and Operation Operation OPERATION After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause A/C compressor damage, and too much can reduce A/C system performance. PAG refrigerant oil is more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. After use, recap the oil container immediately to prevent moisture contamination. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Description and Operation > Page 2888 Refrigerant Oil: Service and Repair REFRIGERANT OIL LEVEL When an A/C system is assembled at the factory, all components except the A/C compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the A/C compressor is dispersed throughout the refrigerant system. The accumulator, A/C evaporator, A/C condenser and the A/C compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of refrigerant oil in the A/C system. This ensures proper lubrication of the A/C compressor. Too little oil will result in damage to the A/C compressor, while too much oil will reduce the cooling capacity of the A/C system and consequently result in higher discharge air temperatures. CAUTION: The refrigerant oil in the R-134a A/C system is unique depending on the A/C compressor used. Use only PAG oils that are designed to work with R-134a refrigerant and the A/C compressor in the vehicle. Always refer to the A/C Underhood Specification Label for the correct oil designation. The oil container should be kept tightly capped until it is ready for use and then tightly capped after use to prevent contamination from dirt and moisture. Refrigerant oil will quickly absorb any moisture it comes in contact with, therefore, special effort must be used to keep all R-134a system components moisture-free. Moisture in the refrigerant oil is very difficult to remove and will cause a reliability problem with the A/C compressor. NOTE: Most reclaim/recycling equipment will measure the lubricant being removed during recovery. This amount of lubricant should be added back into the system. Refer to the reclaim/recycling equipment manufacturers instructions. It will not be necessary to check the oil level in the A/C compressor or to add oil, unless there has been an oil loss. An oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting, a component, or a component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant oil must be added when an A/C accumulator, A/C evaporator or A/C condenser is replaced. See the Refrigerant Oil Capacities chart. The refrigerant oil level in a new A/C compressor must first be adjusted prior to compressor installation. COMPRESSOR OIL DRAIN PROCEDURE CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor. Failure to properly drain and measure the refrigerant oil from the A/C compressor can prevent the A/C system from operating as designed and cause serious compressor damage. The A/C compressor is filled with refrigerant oil from the factory. Use the following procedure to drain and measure refrigerant oil from the A/C compressor. 1. Drain all of the refrigerant oil from the old A/C compressor into a clean measured container. 2. Drain all of the refrigerant oil from the new A/C compressor into a clean measured container. 3. Refill the new A/C compressor with the same amount of refrigerant oil that was drained out of the old compressor. Use only clean refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Install the new A/C compressor onto the engine. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding Brake Bleeding: Service and Repair Manual Bleeding MANUAL BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. 1. Remove reservoir filler caps and fill reservoir. 2. If calipers were overhauled, open all caliper bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. 3. Attach one end of bleed hose (1) to bleed screw and insert opposite end in glass container (2) partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. NOTE: Bleed procedure should be in this order (1) Right rear (2) Left rear (3) Right front (4) Left front. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. 5. Before moving the vehicle verify the pedal is firm and not mushy. 6. Top off the brake fluid and install the reservoir cap. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 2893 Brake Bleeding: Service and Repair Pressure Bleeding PRESSURE BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15-20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 2894 Brake Bleeding: Service and Repair Master Cylinder MASTER CYLINDER BLEEDING A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. 1. Mount master cylinder in vise. 2. Attach bleed tubes to cylinder outlet ports (1). Then position each tube end into reservoir (2). 3. Fill reservoir with fresh brake fluid. 4. Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 2895 Brake Bleeding: Service and Repair ABS Brake Bleeding ABS BRAKE BLEEDING ABS system bleeding requires conventional bleeding methods plus use of a scan tool. The procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the HCU pump and solenoids. A second base brake bleeding procedure is then required to remove any air remaining in the system. 1. Perform base brake bleeding. 2. Connect scan tool to the Data Link Connector. 3. Select ANTILOCK BRAKES, followed by MISCELLANEOUS, then ABS BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 2896 Brake Bleeding: Service and Repair Booster-Hydro-Boost Brake BLEEDING The hydraulic booster is generally self-bleeding, this procedure will normally bleed the air from the booster. Normal driving and operation of the unit will remove any remaining trapped air. 1. Fill power steering pump reservoir. 2. Disconnect fuel shutdown relay and crank the engine for several seconds, Refer to Fuel System for relay location and WARNING. 3. Check fluid level and add if necessary. 4. Connect fuel shutdown relay and start the engine. 5. Turn the steering wheel slowly from lock to lock twice. 6. Stop the engine and discharge the accumulator by depressing the brake pedal 5 times. 7. Start the engine and turn the steering wheel slowly from lock to lock twice. 8. Turn off the engine and check fluid level and add if necessary. NOTE: If fluid foaming occurs, wait for foam to dissipate and repeat steps 7 and 8. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation Air Bag(s) Arming and Disarming: Technical Service Bulletins Air Bag System - Passenger Air Bag Deactivation NUMBER: 08-001-07 REV. B GROUP: Electrical DATE: May 16, 2007 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED. THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION. DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION. SUBJECT: Passenger Air Bag Deactivation MODELS: 2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 0300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakoka 2006 - 2007 (DR) Ram Truck 2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 2901 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet. NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States. PARTS REQUIRED: POLICY: Information Only Disclaimer: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 2902 This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation Fuse: Customer Interest Electrical Systems - Intermittent Component Operation NUMBER:08-016-06 REV. A GROUP: Electrical DATE: July 18, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-016-06, DATED MARCH 22, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF A VEHICLE BODY STYLE. SUBJECT: Intermittent Operation Of Electrical Components Due To Ignition Off Draw (IOD) Fuse Not Being Fully Seated MODELS: 2007 (PM) Caliber **2007 (MK-49) Compass** 2006 - 2007 (DHIDRID1) Ram Truck 2006 - 2007 (PT) Chrysler PT Cruiser DISCUSSION: The Ignition Off Draw (IOD) fuse is used to prevent battery discharge during shipping and long term storage of the vehicles. The IOD fuse is located in the Total Integrated Power Module (TI PM). If the fuse is not completely inserted partial contact of the fuse terminals could occur. When the vehicle is prepped for customer delivery, ensure that the fuse is fully engaged (Fig. 1). The IOD fuse must also be fully released to prevent battery drain from occurring when the vehicle is stored. When the IOD fuse holder is depressed into the carrier, an initial distinct detent will be felt to overcome the "pre-hold position". You must then continue to push straight down on the IOD pre-holder until no further downward movement is encountered. NOTE: If the fuse is not pushed down symmetrically, two detents MAY be felt as each side snaps past the pre-hold position. Push down until no further downward movement is encountered. On 2006 and 2007 PT and PM vehicles the circuits fed by the IOD fuse are: Radio, Security module & siren (BUX), Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Power Mirrors, Clock, Memory Seat, Amplifier, CCN wake-up with ignition off and Homelink. On 2006 and 2007 DR, DH or D1 vehicles the circuits fed by the IOD fuse are: Radio, EVIC, Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Video Screen, CCN wake-up with ignition off, Underhood Lamp, CCN Interior Lighting Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation > Page 2912 POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation Fuse: All Technical Service Bulletins Electrical Systems - Intermittent Component Operation NUMBER:08-016-06 REV. A GROUP: Electrical DATE: July 18, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-016-06, DATED MARCH 22, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF A VEHICLE BODY STYLE. SUBJECT: Intermittent Operation Of Electrical Components Due To Ignition Off Draw (IOD) Fuse Not Being Fully Seated MODELS: 2007 (PM) Caliber **2007 (MK-49) Compass** 2006 - 2007 (DHIDRID1) Ram Truck 2006 - 2007 (PT) Chrysler PT Cruiser DISCUSSION: The Ignition Off Draw (IOD) fuse is used to prevent battery discharge during shipping and long term storage of the vehicles. The IOD fuse is located in the Total Integrated Power Module (TI PM). If the fuse is not completely inserted partial contact of the fuse terminals could occur. When the vehicle is prepped for customer delivery, ensure that the fuse is fully engaged (Fig. 1). The IOD fuse must also be fully released to prevent battery drain from occurring when the vehicle is stored. When the IOD fuse holder is depressed into the carrier, an initial distinct detent will be felt to overcome the "pre-hold position". You must then continue to push straight down on the IOD pre-holder until no further downward movement is encountered. NOTE: If the fuse is not pushed down symmetrically, two detents MAY be felt as each side snaps past the pre-hold position. Push down until no further downward movement is encountered. On 2006 and 2007 PT and PM vehicles the circuits fed by the IOD fuse are: Radio, Security module & siren (BUX), Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Power Mirrors, Clock, Memory Seat, Amplifier, CCN wake-up with ignition off and Homelink. On 2006 and 2007 DR, DH or D1 vehicles the circuits fed by the IOD fuse are: Radio, EVIC, Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Video Screen, CCN wake-up with ignition off, Underhood Lamp, CCN Interior Lighting Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation > Page 2918 POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuses (Integrated Power Module) Fuse: Locations Fuses (Integrated Power Module) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuses (Integrated Power Module) > Page 2921 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuses (Integrated Power Module) > Page 2922 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuses (Integrated Power Module) > Page 2923 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuses (Integrated Power Module) > Page 2924 Fuse: Locations Auxiliary PDC Box (Upfitter Package) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2927 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2928 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2929 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2930 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2931 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2932 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2933 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2935 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2936 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2937 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2938 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2939 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2940 Fuse: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2941 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2942 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2943 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2944 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuses (Integrated Power Module) Fuse: Application and ID Fuses (Integrated Power Module) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 2947 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 2948 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 2949 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 2950 Fuse: Application and ID Auxiliary PDC Box (Upfitter Package) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Description and Operation > Description Fuse: Description and Operation Description DESCRIPTION All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Totally Integrated Power Module (TIPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the TIPM as part of the new vehicle preparation procedures and then disconnect it again until new vehicle delivery to the customer. A laser printed fuse layout map is integral to the TIPM cover to ensure proper fuse identification. The IOD fuse is a 20 ampere mini blade-type fuse. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in the TIPM cavity, and as a fuse holder that conveniently stores the fuse in the same cavity after it has been disconnected. CIRCUITS INCLUDED WITH IOD FUSE - Cluster (CCN) - Diagnostic Connector - Map Lamps - Glove Box Lamp - Courtesy Lamps - Radio - Underhood Lamp Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Description and Operation > Description > Page 2953 Fuse: Description and Operation Operation OPERATION The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from Integrated Power Module (IPM) fuse cavity # 51 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuses (Integrated Power Module) Fuse Block: Locations Fuses (Integrated Power Module) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuses (Integrated Power Module) > Page 2958 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuses (Integrated Power Module) > Page 2959 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuses (Integrated Power Module) > Page 2960 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuses (Integrated Power Module) > Page 2961 Fuse Block: Locations Auxiliary PDC Box (Upfitter Package) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2964 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2965 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2966 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2967 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2968 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2969 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2970 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2971 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2972 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2973 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2974 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2975 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2976 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2977 Fuse Block: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2978 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2979 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2980 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2981 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuses (Integrated Power Module) Fuse Block: Application and ID Fuses (Integrated Power Module) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 2984 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 2985 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 2986 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 2987 Fuse Block: Application and ID Auxiliary PDC Box (Upfitter Package) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) Relay Box: Locations Fuses (Integrated Power Module) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) > Page 2992 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) > Page 2993 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) > Page 2994 Relay Box: Locations Auxiliary PDC Box (Upfitter Package) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) Relay Box: Application and ID Fuses (Integrated Power Module) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 2997 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 2998 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 2999 Relay Box: Application and ID Auxiliary PDC Box (Upfitter Package) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Description and Operation > Description Low Tire Pressure Indicator: Description and Operation Description DESCRIPTION A Tire Pressure Monitor (TPM) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional TPM, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The TPM indicator consists of a stencil-like cutout of an icon that represents a cross-section of a tire with a centered exclamation point in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The TPM indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Description and Operation > Description > Page 3005 Low Tire Pressure Indicator: Description and Operation Operation OPERATION The Tire Pressure Monitor (TPM) indicator gives an indication to the vehicle operator of the status of the TPM system. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Sentry Key REmote Entry Module (SKREEM) over the Controller Area Network (CAN) data bus. The TPM indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provide a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the TPM indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position, the SKREEM sends an electronic TPM indicator lamp-ON message to the cluster to illuminate the TPM indicator for about three seconds as a bulb test. - TPM Indicator Lamp-On Message - Each time the cluster receives an electronic TPM indicator lamp-ON message from the SKREEM, the TPM indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the SKREEM message. The indicator remains illuminated until the cluster receives a lamp-OFF message from the SKREEM or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no TPM lamp-ON or lamp-OFF messages from the SKREEM for six consecutive seconds, the TPM indicator is illuminated by the instrument cluster. The indicator remains controlled and illuminated by the cluster until a valid lamp-ON or lamp-OFF message is received from the SKREEM. - Actuator Test - Each time the cluster is put through the actuator test, the TPM indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The SKREEM performs a self-test each time the ignition switch is turned to the ON position to decide whether the TPM system is in good operating condition and whether the tire inflation pressures are too high or too low. The SKREEM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the instrument cluster turns ON the TPM indicator after the bulb test, it indicates that the inflation pressure of a tire is too low or that a malfunction has occurred and the TPM system is ineffective. For proper diagnosis of the TPM system, the SKREEM, the EMIC, the CAN data bus or the electronic communication related to TPM indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair > Procedures Maintenance Required Lamp/Indicator: Procedures DaimlerChrysler provides no information regarding a Maintenance Required Lamp/Indicator. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair > Procedures > Page 3010 Maintenance Required Lamp/Indicator: Reset Procedure PERFORM SERVICE INDICATOR - RESET The "Perform Service" message will display on the Electronic Vehicle Information Center each time you turn the ignition switch to the ON/RUN position to indicate a emission maintenance is required. To reset the "Perform Service" indicator system (after performing the scheduled maintenance) refer to the following procedure: - 1. Turn the ignition switch to the ON position (Do not start engine). - 2. Press and release the brake pedal two times. - 3. Fully depress the accelerator pedal slowly two times within 10 seconds. - 4. Turn the ignition switch to the OFF/LOCK position. NOTE: If the indicator message illumination when you start the vehicle, the "Perform Service" indicator did not reset. If necessary repeat this procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Description Malfunction Indicator Lamp: Description and Operation Description DESCRIPTION A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. This indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. The MIL consists of a stencil-like cutout of the International Control and Display Symbol icon for Engine in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The MIL is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Description > Page 3015 Malfunction Indicator Lamp: Description and Operation Operation OPERATION The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or the Engine Control Module (ECM) on vehicles with a diesel engine has recorded a Diagnostic Trouble Code (DTC) for an On-Board Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the PCM or ECM over the Controller Area Network (CAN) data bus. The MIL Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the MIL for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the indicator is illuminated for about two seconds as a bulb test. The entire bulb test is a function of the PCM or ECM. - MIL Lamp-On Message - Each time the cluster receives an electronic MIL lamp-ON message from the PCM or ECM, the indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the PCM or ECM message. For some DTCs, if a problem does not recur, the PCM or ECM will send a lamp-OFF message automatically. Other DTCs may require that a fault be repaired and the PCM or ECM be reset before a lamp-OFF message will be sent. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the PCM or ECM for about 10 seconds, the MIL is illuminated by the instrument cluster to indicate a loss of bus communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the PCM or ECM. - Actuator Test - Each time the cluster is put through the actuator test, the MIL indicator will be turned ON during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM or ECM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. The PCM or ECM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the EMIC turns ON the MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and emissions systems may require service. For proper diagnosis of the fuel and emissions systems, the PCM, the ECM, the EMIC, the CAN data bus or the electronic communication related to MIL operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair OIL CHANGE INDICATOR - RESET To reset the "Oil Change Required" indicator (after performing the scheduled maintenance) refer to the following procedure: 1. Turn the ignition switch to the ON position (Do not start engine). 2. Fully depress the accelerator pedal slowly three times within 10 seconds. 3. Turn the ignition switch to the OFF/LOCK position. NOTE: If the "Oil Change Required" indicator message illuminates when you start the vehicle, the indicator did not reset. If necessary repeat this procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation > Description Low Tire Pressure Indicator: Description and Operation Description DESCRIPTION A Tire Pressure Monitor (TPM) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional TPM, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The TPM indicator consists of a stencil-like cutout of an icon that represents a cross-section of a tire with a centered exclamation point in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The TPM indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation > Description > Page 3025 Low Tire Pressure Indicator: Description and Operation Operation OPERATION The Tire Pressure Monitor (TPM) indicator gives an indication to the vehicle operator of the status of the TPM system. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Sentry Key REmote Entry Module (SKREEM) over the Controller Area Network (CAN) data bus. The TPM indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provide a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the TPM indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position, the SKREEM sends an electronic TPM indicator lamp-ON message to the cluster to illuminate the TPM indicator for about three seconds as a bulb test. - TPM Indicator Lamp-On Message - Each time the cluster receives an electronic TPM indicator lamp-ON message from the SKREEM, the TPM indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the SKREEM message. The indicator remains illuminated until the cluster receives a lamp-OFF message from the SKREEM or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no TPM lamp-ON or lamp-OFF messages from the SKREEM for six consecutive seconds, the TPM indicator is illuminated by the instrument cluster. The indicator remains controlled and illuminated by the cluster until a valid lamp-ON or lamp-OFF message is received from the SKREEM. - Actuator Test - Each time the cluster is put through the actuator test, the TPM indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The SKREEM performs a self-test each time the ignition switch is turned to the ON position to decide whether the TPM system is in good operating condition and whether the tire inflation pressures are too high or too low. The SKREEM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the instrument cluster turns ON the TPM indicator after the bulb test, it indicates that the inflation pressure of a tire is too low or that a malfunction has occurred and the TPM system is ineffective. For proper diagnosis of the TPM system, the SKREEM, the EMIC, the CAN data bus or the electronic communication related to TPM indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Specifications Tires: Specifications TIRE REVOLUTIONS PER MILE TIRE REVOLUTIONS PER MILE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tire Tires: Description and Operation Tire TIRES Tires are designed and engineered for each specific vehicle. They provide the best overall performance for normal operation. The ride and handling characteristics match the vehicle's requirements. With proper care they will give excellent reliability, traction, skid resistance, and tread life. Driving habits have more effect on tire life than any other factor. Careful drivers will obtain in most cases, much greater mileage than severe use or careless drivers. A few of the driving habits which will shorten the life of any tire are: - Rapid acceleration - Severe brake applications - High speed driving - Excessive speeds on turns - Striking curbs and other obstacles Radial-ply tires are more prone to irregular tread wear. It is important to follow the tire rotation interval. This will help to achieve a greater tread life. TIRE IDENTIFICATION Tire type, size, aspect ratio and speed rating are encoded in the letters and numbers imprinted on the side wall of the tire. Refer to the chart to decipher the tire identification code. Performance tires have a speed rating letter after the aspect ratio number. The speed rating is not always printed on the tire sidewall. These ratings are: - Q up to 100 mph - S up to 112 mph - T up to 118 mph - U up to 124 mph - H up to 130 mph - V up to 149 mph - W (consult the tire manufacturer for the specific speed rating) - Z more than 149 mph (consult the tire manufacturer for the specific speed rating) An All Season type tire will have either M + S, M & S or M-S (indicating mud and snow traction) imprinted on the side wall. TIRE CHAINS Tire snow chains may be used on certain models. Refer to the Owner's Manual for more information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tire > Page 3031 Tires: Description and Operation Spare / Temporary Tire SPARE / TEMPORARY TIRE The temporary spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 80 KMH (50 MPH). when using the temporary spare tire. Refer to Owner's Manual for complete details. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tire > Page 3032 Tires: Description and Operation Radial - Ply Tires RADIAL - PLY TIRES Radial-ply tires improve handling, tread life and ride quality, and decrease rolling resistance. Radial-ply tires must always be used in sets of four. Under no circumstances should they be used on the front only. They may be mixed with temporary spare tires when necessary. A maximum speed of 80 KMH (50 MPH) is recommended while a temporary spare is in use. Radial-ply tires have the same load-carrying capacity as other types of tires of the same size. They also use the same recommended inflation pressures. The use of oversized tires, either in the front or rear of the vehicle, can cause vehicle drive train failure. This could also cause inaccurate wheel speed signals when the vehicle is equipped with Anti-Lock Brakes. The use of tires from different manufactures on the same vehicle is NOT recommended. The proper tire pressure should be maintained on all four tires. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tire > Page 3033 Tires: Description and Operation Replacement Tires REPLACEMENT TIRES The original equipment tires provide a proper balance of many characteristics such as: - Ride - Noise - Handling - Durability - Tread life - Traction - Rolling resistance - Speed capability It is recommended that tires equivalent to the original equipment tires be used when replacement is needed. Failure to use equivalent replacement tires may adversely affect the safety and handling of the vehicle. The use of oversize tires may cause interference with vehicle components. Under extremes of suspension and steering travel, interference with vehicle components may cause tire damage. WARNING: Failure to equip the vehicle with tires having adequate speed capability can result in sudden tire failure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tire > Page 3034 Tires: Description and Operation Full Size, Spare Wheel With Matching Tire FULL SIZE, SPARE WHEEL WITH MATCHING TIRE The spare is a full usage wheel with a matching tire, It can be used within the (posted legal) speed limits or distance limitations as of the rest of the vehicles four tires. Refer to Owner's Manual for complete details. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Pressure Gauges Tires: Testing and Inspection Pressure Gauges PRESSURE GAUGES A quality air pressure gauge is recommended to check tire pressure. After checking the air pressure, replace valve cap finger tight. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Pressure Gauges > Page 3037 Tires: Testing and Inspection Tire Noise Or Vibration TIRE NOISE OR VIBRATION Radial-ply tires are sensitive to force impulses caused by improper mounting, vibration, wheel defects, or possibly tire imbalance. To find out if tires are causing the noise or vibration, drive the vehicle over a smooth road at varying speeds. Note the noise level during acceleration and deceleration. The engine, differential and exhaust noises will change as speed varies, while the tire noise will usually remain constant. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Pressure Gauges > Page 3038 Tires: Testing and Inspection Tread Wear Indicators TREAD WEAR INDICATORS Tread wear indicators (3) are molded into the bottom of the tread grooves. When tread depth is 1.6 mm (1/16 in.), the tread wear indicators (3) will appear as a 13 mm (1/2 in.) band. Tire replacement is necessary when indicators appear in two or more grooves or if localized balding occurs. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Pressure Gauges > Page 3039 Tires: Testing and Inspection Tire Wear Patterns TIRE WEAR PATTERNS Under inflation will cause wear on the shoulders of tire. Over inflation will cause wear at the center of tire. Excessive camber causes the tire to run at an angle to the road. One side of tread is then worn more than the other. Excessive toe-in or toe-out causes wear on the tread edges and a feathered effect across the tread. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Pressure Gauges > Page 3040 Tires: Testing and Inspection Tire/Vehicle Lead TIRE/VEHICLE LEAD Use the following Vehicle Lead Diagnosis And Correction Chart to diagnose and correct a vehicle lead or drift problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures Tires: Procedures Cleaning TIRES Remove the protective coating on the tires before delivery of a vehicle. This coating may cause deterioration of the tires. To remove the protective coating, apply warm water and let it soak for a few minutes. Afterwards, scrub the coating away with a soft bristle brush. Steam cleaning may also be used to remove the coating. NOTE: DO NOT use gasoline, mineral oil, oil-based solvent or a wire brush for cleaning. Tire Inflation Pressures TIRE INFLATION PRESSURES WARNING: Over or under inflated tires can affect vehicle handling and tread wear. This may cause the tire to fail suddenly, resulting in loss of vehicle control. Under inflation will cause rapid shoulder wear (1), tire flexing, and possible tire failure. Over inflation will cause rapid center wear (1) reduction in the tire's ability to cushion shocks. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 3043 Improper inflation can cause: - Uneven wear patterns - Reduced tread life - Reduced fuel economy - Unsatisfactory ride - Vehicle drift For proper tire pressure specification refer to the vehicles Owners Manual. Tire Pressure For High Speed Operation TIRE PRESSURE FOR HIGH SPEEDS For proper tire pressure specification refer to the Owners Manual. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 3044 Tires: Removal and Replacement TIRE REPAIR AREA For proper repairing, a radial tire must be removed from the wheel. Repairs should only be made if the defect, or puncture, is in the tread area (1). The tire should be replaced if the puncture is located in the sidewall. Deflate tire completely before removing the tire from the wheel. Use lubrication such as a mild soap solution when dismounting or mounting tire. Use tools free of burrs or sharp edges which could damage the tire or wheel rim. Before mounting tire on wheel, make sure all rust is removed from the rim bead and repaint if necessary. Install wheel on vehicle, and tighten to proper torque specification. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information Wheels: Technical Service Bulletins Wheels/Tires - Chrome Clad Wheel Balancing Information NUMBER: 22-002-09 GROUP: Wheels/Tires DATE: July 29, 2009 SUBJECT: Chrome Clad Wheel Adapters For Proper Balancing OVERVIEW: This bulletin describes the use of proper wheel adapters when mounting Chrome Clad wheels to wheel balancing equipment. MODELS: 2004-2008 (CS) Pacifica 2007 - 2009 (D1) Ram Truck (3500 Pick Up) 2007 - 2010 DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2004 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2009-2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2008 - 2010 (JS27) Sebring Convertible 2007 - 2010 (JS41) Sebring/Avenger 2007-2010 (KA) Nitro 2002-2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2008 - 2010 (KK) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005-2010 (ND) Dakota 2007 - 2001 (PM) Caliber 2001 - 2009 (PT) Chrysler PT Cruiser 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2008 - 2010 (RI) Town & Country/Grand Caravan Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information > Page 3049 2008 - 2010 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005-2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander NOTE: This information applies to any model equipped with Chrome Clad Wheels. DISCUSSION: Models equipped with Chrome Clad wheels require specific piloting on balance equipment to properly center the wheel and prevent damage to the chrome clad surface. The chrome cladding is not removable or replaceable and has cladding tabs that extend into the wheel bore. Traditional high-taper cones will come into contact with the cladding tabs rather than properly seat on the hub bore chamfer. Many modern aluminum wheel designs cannot be mounted with traditional cones. Direct-Fit Collets should be used to properly mount clad wheels on balance equipment (Fig 1). SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: This kit includes the adapters for all Dodge, Chrysler & Jeep models with clad wheels. Individual adapters for specific wheel sizes can be ordered separately. To order a kit or individual adapters, contact Pentastar Service Equipment @ 1-800-223-5623. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Description - Wheels Wheels: Description and Operation Description - Wheels WHEELS Original equipment wheels are designed for the specified Maximum Vehicle Capacity. All models use steel or aluminum drop center wheels. Aluminum wheels require special balance weights and alignment equipment. 1. On vehicles equipped with dual rear wheels, the rim is an eight stud hole pattern wheel. The wheels have a flat mounting surface (1). 2. The slots (1) in the wheel must be aligned to provide access to the valve stem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Description - Wheels > Page 3052 Wheels: Description and Operation Description - Wheel Design WHEEL DESIGN The rim size is on the vehicle safety certification label located on the drivers door shut face. Original equipment wheels/rims are designed for operation up to the specified maximum vehicle capacity. All models use stamped steel, cast aluminum or forged aluminum wheels. Every wheel has raised sections between the rim flanges (1) and rim drop well (3) called safety humps. Initial inflation of the tire forces the bead over these raised sections. In case of rapid loss of air pressure, the raised sections help hold the tire on the wheel. The wheel studs and nuts are designed for specific applications. All aluminum and some steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Do not use replacement studs or nuts with a different design or lesser quality. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 3053 Wheels: Testing and Inspection WHEEL INSPECTION Inspect wheels for: - Excessive runout - Dents, cracks or irregular bends - Damaged wheel stud (lug) holes - Air Leaks NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged, an original equipment replacement wheel should be used. When obtaining replacement wheels, they must be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: Failure to use equivalent replacement wheels may adversely affect the safety and handling of the vehicle. WARNING: Replacement with used wheels is not recommended. The service history of the wheel may have included severe treatment or very high mileage. The rim could fail without warning. WARNING: DaimlerChrysler Corporation does not recommend that customers use "reconditioned" wheels (wheels that have been damaged and repaired) because they can result in a sudden catastrophic wheel failure which could cause loss of control and result in injury or death. For clarification: - Cosmetic refinishing for the purpose of repairing a superficial flaw is an acceptable procedure providing it is limited to paint or clear coat only, the wheel is not modified in any way, and there is no exposure to paint curing heat over 200 degrees Fahrenheit. - Damaged wheels are those which have been bent, broken, cracked or sustained some other physical damage which may have compromised the wheel structure. - Repaired indicates that the wheel has been modified through bending, welding, heating, straightening, or material removal to rectify damage. - Re-plating of chrome plated wheels is not an acceptable procedure nor is chrome plating of original equipment painted or polished wheels, as this may alter mechanical properties and affect fatigue life. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications WHEEL BEARING LUBRICANT Mopar Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front - Independent Front Suspension Wheel Bearing: Service and Repair Front - Independent Front Suspension Removal 4X4 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper and rotor. 4. Remove the ABS wheel speed sensor if equipped. 5. Remove the halfshaft nut. NOTE: Do not strike the knuckle with a hammer to remove the tie rod end or the ball joint. Damage to the steering knuckle will occur. 6. Remove the tie rod end nut and separate the tie rod from the knuckle using remover 9360. 7. Remove the upper ball joint nut and separate the upper ball joint from the knuckle using remover 9360. 8. Pull down on the steering knuckle to separate the halfshaft (2) from the hub/bearing. 9. Remove the three hub/bearing mounting bolts (1) from the steering knuckle. 10. Slide the hub/bearing out of the steering knuckle. 11. Remove the brake dust shield. Installation 4X4 1. Install the brake dust shield (2). 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts to 163 Nm (120 ft. lbs.). 3. Install the brake rotor and caliper. 4. Install the ABS wheel speed sensor if equipped. 5. Install the upper ball joint nut to the steering knuckle and tighten to 54 Nm (40 ft. lbs.) (on 1500 series only an additional 90° turn). 6. Install the tie rod end nut to the steering knuckle and tighten to 61 Nm (45 ft. lbs.) then an additional 90°. 7. Install the halfshaft nut and tighten to 251 Nm (185 ft. lbs.). 8. Install the wheel and tire assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front - Independent Front Suspension > Page 3059 9. Remove the support and lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front - Independent Front Suspension > Page 3060 Wheel Bearing: Service and Repair Front - Link/Coil Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the hub extension (1) mounting nuts and remove the extension from the rotor if equipped. 4. Remove the brake caliper. 5. Remove the cotter pin (2) and the hub nut (1) from the axle shaft. 6. Remove the caliper adapter. 7. Remove the disc brake rotor. 8. Disconnect the wheel speed sensor wire. 9. Remove the hub/bearing 4 mounting bolts and remove the hub/bearing. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front - Independent Front Suspension > Page 3061 1. Position the brake shield (1) on bolts. 2. Install the hub/bearing to the knuckle. Tighten the hub/bearing bolts (2) to 202 Nm (149 ft. lbs.) 3. Install the hub nut and tighten to 356 Nm (263 ft. lbs.). 4. Install the wheel speed sensor to the hub. 5. Install the disc brake rotor. 6. Install the brake caliper adapter with the caliper. 7. Install the hub extension and nuts to the front rotor. Tighten nuts to 130 Nm (96 ft.lbs). HD DRW ONLY. 8. Install the wheel and tire assemblies. 9. Remove the support and lower the vehicle. 10. Apply the brakes several times to seat the brake shoes and caliper piston. Do not move the vehicle until a firm brake pedal is obtained. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Removal Wheel Cover: Service and Repair Removal REMOVAL NOTE: The hub caps must be removed before raising the vehicle off the ground. NOTE: You must use the flat end of the hub/cap remover/installer combination tool to pry off the wheel skins. Insert the flat tip completely and using a back and forth motion, loosen the wheel skin. repeat this procedure around the tire until the wheel skin pops off. 1. On 2500/3500 single rear wheel (SRW) models, insert a hub/cap remover/installer combination tool using the blade on the end of the tool to pry the cap off in a back and forth motion. 2. On 3500 models with dual rear wheels (DRW), you must first remove the hub caps. The hub/cap remover/installer combination tool must be inserted in the pry off notch of the rear hub caps. 3. Position the hub/cap remover/installer combination tool and pull out on the tool firmly. The cap should come off. NOTE: Failure to use a back and forth motion could damage the wheel skin chrome finish. 4. The wheel skins can now be removed from the wheel. Use the flat end of the lug nut wrench to pry off the wheel skins. Make sure that the flat end is inserted and use a back and forth motion to remove the wheel skin. 5. On 3500 models front hub caps use the hub/cap remover/installer combination tool to pry off the cap in a back and forth motion. The wheel skins can now be removed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Removal > Page 3066 Wheel Cover: Service and Repair Installation Front FRONT 1. Align the valve stem with the notch in the wheel skin. 2. Seat on side of the wheel skin's wire retainer on to the wheel. 3. Using a rubber mallet, strike the opposite side of the wheel skin until the skin is properly seated. NOTE: The wheel skin and the hub cap are fully seated when there is a consistant gap between the skin/ cap and the wheel. 4. Tug on the hub cap/wheel skin to ensure that they are properly installed. Rear REAR 1. Install one 1 1/2 in. valve stem extension on each rear inner wheel. NOTE: A 3/8 in. drive 10mm deep wheel socket with a 10 in. or greater extension can be used to remove the existing valve stem cap and install the extension. 2. Install one 1 in. valve stem extension on each outer wheel. 3. Align the cooling windows of the wheel skin with the cooling windows of the wheel. Seat one side of the wheel skin's retainer onto the wheel. Using a rubber mallet, strike thew wheel skin on the outer circumference. Strike at several locations around the circumference until the skin is fully seated. NOTE: The wheel skin and the hub cap are fully seated when there is a consistent gap between the skin/cap and the wheel. 4. Tug on the hub/cap wheel skin to ensure that they are properly installed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Hub Nut Tighten to .............................................................................................................................. ............................................................... 356 Nm (263 ft. lbs.) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications TORQUE Torque Specifications Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Removal Wheel Fastener: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, caliper adapter and rotor. 4. Remove the wheel speed sensor from the hub. 5. Press the stud from the hub using remover C-4150A (1). 6. Remove the stud (2) from the hub (1) through the backing plate access hole (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Removal > Page 3076 Wheel Fastener: Service and Repair Installation INSTALLATION 1. Install the new stud (2) into the hub flange (1). 2. Install three proper sized washers onto the stud, then install lug nut with the flat side of the nut against the washers. 3. Tighten the lug nut until the stud is pulled into the hub flange. Verify that the stud is properly seated into the flange. 4. Remove the lug nut and washers. 5. Install the brake rotor, caliper adapter, and caliper. 6. Install the wheel speed sensor. 7. Install the wheel and tire assembly, use new lug nut on the stud or studs that were replaced. 8. Remove the support and lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure (Minimum) ...................................................................................................... ...................................................................... 350 psi. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 3082 Compression Check: Testing and Inspection CYLINDER COMPRESSION/LEAKAGE TESTS CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure batteries are completely charged and the engine starter motor is in good operating condition. Otherwise, the indicated compression pressures may not be valid for diagnostic purposes. 1. Disconnect the fuel inlet line to the fuel filter housing. Plug the fuel line from the fuel tank. NOTE: Failure to plug fuel line will result in fuel leak. 2. Remove fuel transfer pump relay from PDC. 3. Start the engine and idle until the engine stalls (runs out of fuel). 4. Remove the cylinder head cover. 5. Remove the cylinder head cover carrier gasket. 6. Remove the high pressure fuel line between the cylinder head and fuel rail for the cylinder to be tested. Use tool 9864 to cap this fuel rail on the cylinder being tested. 7. Remove the fuel connector tube nut and fuel connector tube. 8. Remove the exhaust rocker lever. 9. Use Tool 9010 to remove the injector and copper sealing washer. 10. Install the exhaust rocker lever and torque to 36 Nm (27 ft. lbs.). 11. Cover the remaining rocker levers with clean shop towels to prevent any oil splatter under the hood. 12. Place a rag over the compression test tool fitting. Crank the engine for 2-3 seconds to purge any fuel that may have drained into the cylinder when the injector was removed. 13. Connect the compression test gauge. 14. Crank the engine for 5 seconds and record the pressure reading. Repeat this step three times and calculate the average of the three readings. NOTE: The minimum cylinder pressure is 350 psi. Cylinder pressure should be within 20% from cylinder to cylinder. 15. Combustion pressure leakage can be checked if cylinder pressure is below the specification. Perform the leakage test procedure on each cylinder according to the tester manufacturer instructions. 16. Upon completion of the test check and erase any engine related fault codes. CYLINDER COMBUSTION PRESSURE LEAKAGE The combustion pressure leakage test provides an accurate means for determining engine condition. Combustion pressure leakage testing will detect: - Exhaust and intake valve leaks (improper seating). - Leaks between adjacent cylinders or into water jacket. - Any causes for combustion/compression pressure loss 1. Start and operate the engine until it attains normal operating temperature. 2. Disconnect injector harness connectors. 3. Disconnect CCV tube and breather drain tube from valve cover. 4. Remove the cylinder head cover. 5. Disconnect harness from injectors. 6. Remove the cylinder head cover carrier gasket. 7. Bring the cylinder to be tested to TDC. 8. Remove the high pressure fuel line between the cylinder head and the fuel rail for the cylinder to be tested. 9. Install capping Tool 9864 onto the rail. 10. Remove the high pressure connector nut and high pressure connector with Tool 9015. 11. Remove the exhaust and intake rocker lever. 12. Use Tool # 9010 to remove the injector and copper sealing washer. 13. Install compression test Tool # 9007 into the injector bore. 14. Connect the leakage tester and perform the leakage test procedure on each cylinder according to the tester manufacturer's instructions. 15. Upon completion of the test check and erase any engine related fault codes. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures Camshaft: Procedures INSPECTION Camshaft Camshaft Dimensions 1. Inspect the valve lobes (1) and bearing journals (2) for cracks, pitting, scoring, or generally excessive wear. Replace any camshaft that exceeds the allowable limits. 2. Measure the bearing journals and lobes. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 3088 CAUTION: If Camshaft lobes are worn, requiring camshaft replacement, it is necessary to replace the tappets also. Camshaft Bushing/Bores Camshaft bores No. 2-6 do not use a bushing. 1. Inspect the camshaft bushing and bores for signs of excessive wear. 2. Measure the camshaft bushing and bores with a telescoping bore gauge and micrometer. 3. Inspect the camshaft bushing (1) oil holes for alignment with cylinder block. Camshaft Gear Inspect the camshaft gear for cracks (gear and hub), and chipped/broken/fretted teeth. If replacement is necessary, camshaft and gear are replaced as an assembly. Thrust Plate Camshaft Thrust Plate Thickness Chart Inspect the camshaft thrust plate for excessive wear in the camshaft contact area. Measure thrust plate thickness using the CAMSHAFT THRUST PLATE THICKNESS CHART. Replace any thrust plate that falls outside of these specifications: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 3089 Camshaft: Removal and Replacement Camshaft - Removal CAMSHAFT 1. Disconnect both battery negative cables. 2. Recover A/C refrigerant (if A/C equipped). 3. Raise vehicle on hoist. 4. Drain engine coolant into container suitable for re-use. 5. Lower vehicle. 6. Remove radiator upper hose. 7. Remove viscous fan/drive/shroud assembly. 8. Disconnect the coolant recovery bottle hose from the radiator filler neck. 9. Disconnect lower radiator hose from radiator outlet. 10. Automatic Transmission models: Disconnect transmission oil cooler lines from front of radiator using Special Tool 6931 (unless equipped with finger-release disconnect). 11. Remove radiator mounting screws and lift radiator out of engine compartment. 12. Remove upper radiator support panel. 13. If A/C equipped, disconnect A/C condenser refrigerant lines. 14. Disconnect charge air cooler piping from the cooler inlet and outlet. 15. Remove the two charge air cooler mounting bolts. 16. Remove charge air cooler (and A/C condenser if equipped) from vehicle. 17. Remove accessory drive belt. 18. Remove accessory drive belt tensioner. 19. Remove the fan support/hub assembly. 20. Remove crankshaft damper. 21. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar the sealing surfaces. Remove dust seal with cover. 22. Using Special Tool 7471-B Crankshaft Barring Tool, rotate the crankshaft to align the timing marks on the crankshaft and the camshaft gears. 23. Remove the cylinder head cover. 24. Remove the rocker arms, cross heads, and push rods. Mark each component so they can be installed in their original positions. NOTE: The #5 cylinder intake and the #6 cylinder intake and exhaust pushrods are removed by lifting them up and through the provided cowl panel access holes. Remove the rubber plugs to expose these relief holes. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 3090 25. Raise the tappets as follows, using the wooden dowel rods provided with the Miller Tool Kit 8502. a. Insert the slotted end of the dowel rod into the tappet. The dowel rods for the rear two cylinders will have to be cut for cowl panel clearance. Press firmly to ensure that it is seated in the tappet. b. Raise the dowel rod to bring the tappet to the top of its travel, and wrap a rubber band around the dowel rods to prevent the tappets from dropping into the crankcase. c. Repeat this procedure for the remaining cylinders. 26. Verify that the camshaft timing marks are aligned with the crankshaft mark. 27. Remove the bolts from the thrust plate. 28. Remove engine mount through bolts. 29. Install engine support fixture special tool #8534, and steel bracket/wing nut special tool #8534A. 30. Raise engine enough to allow camshaft removal. 31. Remove the camshaft, gear and thrust plate. Camshaft - Installation CAMSHAFT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 3091 1. Lubricate the camshaft bushing and bores with fresh engine oil or suitable equivalent. 2. Liberally coat the camshaft lobes, journals, and thrust washer with fresh engine oil or suitable equivalent. CAUTION: When installing the camshaft, DO NOT push it in farther than it will go with the thrust washer in place. 3. Install the camshaft and thrust plate. Align the timing marks as shown. 4. Install the thrust plate bolts and tighten to 24 Nm (18 ft. lbs.) torque. 5. Measure camshaft back lash and end clearance. 6. Remove the wooden dowel rods and rubber bands from the tappets. 7. Lubricate the push rods with engine oil and install in their original location. Verify that they are seated in the tappets. 8. Lubricate the valve tips with engine oil and install the crossheads in their original locations. 9. Lubricate the crossheads and push rod sockets with engine oil and install the rocker arms and pedestals in their original locations. Tighten bolts to 36 Nm (27 ft. lbs.) torque. 10. Verify valve lash adjustment. 11. Install the cylinder head cover. 12. Install gear housing cover. Install front crankshaft dust seal. 13. Install the crankshaft damper. 14. Install the fan support/hub assembly. 15. Install the power steering pump. 16. Install accessory drive belt tensioner. Torque bolt to 43 Nm (32 ft. lbs.). 17. Install the accessory drive belt. 18. Install the charge air cooler (with a/c condenser and auxiliary transmission oil cooler, if equipped) and tighten the mounting bolts to 2 Nm (17 in. lbs.) torque. 19. Connect charge air cooler inlet and outlet pipes. Tighten clamps to 11 Nm (95 in. lbs.) torque. 20. Install the radiator upper support panel. 21. Close radiator petcock and lower the radiator into the engine compartment. Tighten the mounting bolts to 11 Nm (95 in. lbs.) torque. 22. Raise vehicle on hoist. 23. Connect radiator lower hose and install clamp. 24. Connect transmission auxiliary oil cooler lines (if equipped). 25. Lower vehicle. 26. Install the fandrive/shroud assembly. 27. Install the coolant recovery and windshield washer fluid reservoirs to the fan shroud. 28. Connect the coolant recovery hose to the radiator filler neck. 29. Add engine coolant. 30. Charge A/C system with refrigerant (if A/C equipped). 31. Connect the battery negative cables. 32. Start engine and check for engine oil and coolant leaks. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 3092 Camshaft Bearings - Removal CAMSHAFT BEARINGS NOTE: Measure the diameter of each bore. If the camshaft bore for the cam bushing is worn beyond the limit, install a new service bushing. Inspect the rest of the camshaft bores for damage or excessive wear.If the bores without a bushing are worn beyond the limit, the engine must be removed for machining and installation of service bushings. If badly worn, replace the cylinder block. 1. Remove the camshaft. 2. Remove the bushing from the No.1 bore. 3. Mark the cylinder block so you can align the oil hole in the cylinder block with the oil hole in the bushing. Camshaft Bearings - Installation CAMSHAFT BEARINGS 1. Apply a coating of Loctite(R) 640 Adhesive to the backside of the new bushing. Avoid getting adhesive in the oil hole. 2. Use a universal cam bushing installation tool and install the front bushing (1) so that it is even with the front face of the cylinder block. The oil hole must be aligned. A 3.2 mm (0.128 inch) diameter rod must be able to pass through the hole. 3. Measure the installed bushings at the front bore. The minimum inside diameter is 54.083 mm (2.1293 inch), and the maximum inside diameter is is 54.147 mm. (2.1318 in.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures Lifter / Lash Adjuster: Procedures Cleaning CLEANING Clean tappet with a suitable solvent. Rinse in hot water and blow dry with a clean shop rag or compressed air. Inspection INSPECTION 1. Visually inspect the tappet the tappet socket, stem, and face for excessive wear, cracks, or obvious damage. 2. Measure the tappet stem diameter. Replace the tappet if it falls below the minimum size. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 3097 Lifter / Lash Adjuster: Removal and Replacement Removal REMOVAL NOTE: This procedure requires use of Miller Tool 8502 Tappet Replacement Kit. 1. Remove camshaft. 2. Insert the trough (1) (provided with tool kit) the full length of the camshaft bore. Make sure the cap end goes in first and the open side faces up (towards tappets). 3. Remove only one tappet at a time. Remove rubber band from one cylinder pair and attach tappet dowel not being removed to the next cylinder pair. 4. Raise dowel rod (disengage from tappet) and allow tappet to fall into trough. 5. Carefully remove trough (do not rotate) and tappet. If the tappet is not being replaced, mark it so it can be installed in its original location. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 3098 6. Re-install trough (1) and repeat procedure on remaining tappets. Installation INSTALLATION 1. Insert the trough (1) the full length of the camshaft bore. Again, make sure the cap end goes in first and the open side faces up (towards tappets). 2. Lower the tappet installation tool through the push rod hole and into the trough. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 3099 3. Retrieve the tappet installation tool using the hooked rod provided with the tool kit. 4. Lubricate the tappet with clean engine oil or suitable equivalent and install the tappet to the installation tool. 5. Pull the tappet up and into position. If difficulty is experienced getting the tappet to make the turn into the tappet bore, wiggle the trough while gently pulling up on the tappet. 6. With the tappet in place, rotate the trough one half turn so the open side is down (toward crankshaft). 7. Remove the tappet installation tool from the tappet. 8. Re-install a dowel rod and secure the rod with a rubber band. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 3100 9. Rotate the trough one half turn and repeat the procedure for the remaining tappets. 10. Install the camshaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Description and Operation Rocker Arm Assembly: Description and Operation DESCRIPTION The unique intake and exhaust rocker arms have their own rocker shafts and are lubricated by passages intersecting the cylinder block main oil rifle. Crossheads are used, which allow each rocker arm to operate two valves. The solid push rods are hardened at the rocker arm and tappet contact areas for superior strength and durability. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures Rocker Arm Assembly: Procedures Cleaning CLEANING Clean all components in a suitable solvent. If necessary, use a wire brush or wheel to remove stubborn deposits. Rinse in hot water and blow dry with compressed air. Inspect oil passages in rocker arms and pedestals. Apply compressed air to lubrication orifices to purge contaminants. Inspection INSPECTION Rocker Arms 1. Remove rocker shaft and inspect for cracks and excessive wear in the bore or shaft. Remove socket and inspect ball insert and socket for signs of wear. Replace retainer if necessary. Measure the rocker arm bore and shaft. Push Rods Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 3106 Inspect the push rod ball and socket for signs of scoring. Check for cracks where the ball and the socket are pressed into the tube. Roll the push rod on a flat work surface with the socket end hanging off the edge. Replace any push rod that appears to be bent. Crossheads Inspect the crossheads for cracks and/or excessive wear on rocker lever and valve tip mating surfaces. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 3107 Rocker Arm Assembly: Removal and Replacement Removal REMOVAL 1. Disconnect the battery negative cables. 2. Remove cylinder head cover. 3. Remove the rocker arm/pedestal fasteners and remove rocker arm (1) and pedestal (2) from cylinder head. Mark the arms and pedestals so they can be installed in their original position. CAUTION: When removing the rocker arms, the sockets may come loose and fall into the engine. Make sure they stay with the arm upon removal/installation. 4. Lift the push rod(s) up and out of the engine. Mark them so they can be installed in their original position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 3108 NOTE: The #5 cylinder intake and exhaust, and #6 cylinder intake and exhaust push rods must be raised through the provided cowl panel access holes. 5. Lift the crossheads off of the valve stems. Mark them so they can be installed in their original position. Installation INSTALLATION 1. If previously removed, install the push rods in their original location. Verify that they are seated in the tappets. 2. Lubricate the valve tips and install the crossheads in their original locations. 3. Lubricate the crossheads and push rod sockets and install the rocker arms and pedestals in their original locations. Tighten bolts to 36 Nm (27 ft. lbs.) torque. 4. Verify valve lash adjustment. 5. Install cylinder head cover. 6. Connect battery negative cables. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Connecting Rods Connecting Rods Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 3113 Connecting Rod Bearing: Service and Repair CONNECTING ROD BEARING AND CRANKSHAFT JOURNAL CLEARANCE 1. Measure the connecting rod bore with bearings removed and the bolts tightened to 100 Nm (73 ft. lbs.) torque.. 2. Measure the connecting rod bore with the bearings installed and the bolts tightened to 100 Nm (73 ft. lbs.) torque. Measure within 20° arc from each side of the parting line. Also measure 90° from parting line. Record the smallest and largest diameter. Measure the diameter of the rod journal at the location shown. Calculate the average diameter for each side of the journal. Determine minimum bearing clearance by calculating the differance between the smallest connecting rod bore diameter with the bearing installed and the average diameter for each side of the crankshaft journal. Determine the maximum bearing clearance by calculating the difference between the largest connecting rod bore diameter and the average diameter with the bearing installed for each side of the crankshaft journal. If the crankshaft is within limits, replace the bearing. If the crankshaft is out of limits, grind the crankshaft to the next smaller size and use oversize rod bearings. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Connecting Rods Connecting Rods Connecting Rod-Bolts Step 1 .................................................................................................................................................. ................................................. 30 Nm (22 ft. lbs.) Step 2 ................................................................... ................................................................................................................................ 60 Nm (44 ft. lbs.) Step 3 .................................................................................................................................................. .................................................. Rotate 60 degrees Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 3117 Connecting Rod: Description and Operation DESCRIPTION PISTONS The piston is constructed of aluminum and is gravity cast, free floating design. The piston incorporates a centrally located high swirl combustion bowl, and utilizes a "keystone" style top compression ring, and a "Tapered Face" intermediate ring, for superior cylinder wall scraping. Piston cooling nozzles cool the piston and pin with engine oil supplied by the crankshaft main journals. All pistons are gallery cooled and utilize J-jet piston cooling nozzles. Pistons are directional in order to provide clearance to piston cooling nozzles. CONNECTING RODS The connecting rods are a split angle design. They have a pressed-in-place wrist pin bushing that is lubricated by piston cooling nozzle oil spray. Machined connecting rods are no longer used in the diesel engine. Do not install machined connecting rods into an engine that has fractured split connecting rods. Fractured split connecting rods are first manufactured as a single piece and then fractured into two pieces. Fractured split connecting rods can be identified by a rough and irregular surface at the connecting rod split face. To properly assemble the rod cap to the connecting rod, the bearing tangs on the connecting rod and cap must be located on the same side of the rod. The long end of the connecting rod must be assembled on the intake or camshaft side of the engine. Each matched fractured split connecting rod and cap is an assembly and are not interchangeable. If a connecting rod or cap is damaged, the entire assembly must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures Connecting Rod: Procedures Piston and Connecting Rod - Cleaning CLEANING CAUTION: DO NOT use bead blast to clean the pistons. DO NOT clean the pistons and rods in an acid tank. PISTON Clean the pistons and pins in a suitable solvent, rinse in hot water and blow dry with compressed air. Soaking the pistons over night will loosen most of the carbon build up. De-carbon the ring grooves with a broken piston ring and again clean the pistons in solvent. Rinse in hot water and blow dry with compressed air. CONNECTING ROD Clean the connecting rods in a suitable solvent, rinse in hot water and blow dry with compressed air. Piston and Connecting Rod - Inspection CONNECTING ROD Inspect the connecting rod for damage and wear. The I-Beam section of the connecting rod cannot have dents or other damage. Damage to this part can cause stress risers which will progress to breakage. Measure the connecting rod pin bore (1). The maximum diameter is 40.042 mm (1.5765 inch), minimum diameter is 40.019 mm (1.5756 inch). If out of limits, replace the connecting rod. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures > Page 3120 Connecting Rod: Removal and Replacement Piston and Connecting Rod - Removal REMOVAL 1. Disconnect the battery cables. 2. Remove the cylinder head. 3. Remove the oil pan and suction tube. 4. Remove bolts and the block stiffener. 5. Using Miller Tool 7471-B crankshaft barring tool, rotate the crankshaft so all of the pistons are below TDC. 6. Before removing the piston(s) from the bore(s): a. Remove any carbon ridge formations or deposits at the top of the bore with a dull scraper or soft wire brush. b. If cylinder bore wear ridges are found, use a ridge reamer to cut the ridge from the bore. DO NOT remove more metal than necessary to remove the ridge. 7. Remove the J-jet cooling nozzles. NOTE: If cylinders have ridges, the cylinders are oversize and will more than likely need boring. 8. Using a hammer and steel stamp, stamp the cylinder number in the top of each piston. The front of the piston is identified by a stamping on the top of the piston. DO NOT stamp in the outside 5 mm (.197 in.) of the piston diameter. DO NOT stamp over the piston pin. 9. Mark the connecting rod and cap with the corresponding cylinder numbers. 10. Remove the connecting rod bolts and rod caps. Use care so the cylinder bores and connecting rods are not damaged. 11. Use a hammer handle or similar object to push the piston and connecting rod through the cylinder bore. 12. Store the piston/rod assemblies in a rack. Piston and Connecting Rod - Installation INSTALLATION 1. Lubricate the cylinder bores with clean engine oil. 2. Generously lubricate the rings and piston skirts with clean engine oil. 3. Orientate the rings on the piston. 4. Compress the rings using a piston ring compressor tool (1). If using a strap-type ring compressor, make sure the inside end of the strap does not hook on a ring gap and break the ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures > Page 3121 5. Bar the crankshaft so the rod journal for the piston to be installed is at BDC (Bottom Dead Center). 6. Make sure the front of the piston is oriented properly according to the marking on the top of the piston and the connecting rod is oriented properly. 7. Position the piston and rod assembly into the cylinder bore with the front of the piston oriented properly according to the stamping in the top of the piston. Use care when you install the piston and connecting rod so the cylinder bore is not damaged. The long side of the connecting rod must be installed on the exhaust side of the engine. 8. Push the piston into the bore until the top of the piston is approximately 50 mm (2 inch) below the top of the block. Carefully pull the connecting rod onto the crankshaft journal. 9. Use clean engine oil to lubricate the threads and under the heads of the connecting rod bolts. 10. For fractured/split type connecting rods, the long end of the rod must be installed away from the intake side of the engine. a. The connecting rod split/face must face toward the same side as the piston notch feature on the skirt. The split face will face toward the exhaust side of the engine if properly installed. 11. Install the rod cap and bolts to the connecting rod. Tighten the connecting rod bolts evenly in 3 steps. - Tighten the bolts to 30 Nm (22 ft. lbs.) torque. - Tighten the bolts to 60 Nm (44 ft. lbs.) torque. - Rotate 60° clockwise. 12. The crankshaft must rotate freely. Check for freedom of rotation as the caps are installed. If the crankshaft does not rotate freely, check the installation of the rod bearing and the bearing size. 13. Measure the side clearance between the connecting rod and the crankshaft. DO NOT measure the clearance between the cap and crankshaft. 14. Install J-jet piston cooling nozzles. 15. Install block stiffener. Torque to 43 Nm (32 ft. lbs.). 16. Install the suction tube and oil pan. 17. Install the cylinder head onto the engine. 18. Install a new filter and fill the crankcase with new engine oil. Prefill the filter with clean oil. 19. Connect the battery negative cables and start engine. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Crankshaft Main Cap-Bolts (Previously Used) Step 1 .................................................................................................................................................. .................................................. 60 Nm (44 ft. lbs.) Step 2 .................................................................. .................................................................................................................................. 80 Nm (59 ft. lbs.) Step 3 .......................................................................................................................................... ...................................................................... Rotate 90° Crankshaft Main Cap-Bolts (New Main Bearing Capscrews) Step 1 .................................................................................................................................................. ............................................... 120 Nm (89 ft. lbs.) Step 2 ................................................................... .............................................................................................................................. Loosen Completely Step 3 .................................................................................................................................................. ................................................. 60 Nm (44 ft. lbs.) Step 4 ................................................................... ................................................................................................................................. 85 Nm (63 ft. lbs.) Step 5 .......................................................................................................................................... ......................................................... Rotate 120 degrees Calculate the main bearing journal to bearing clearance. Maximum clearance is 0.119 mm (0.00475 inch) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 3125 Crankshaft Main Bearing: Service and Repair MAIN BEARING CLEARANCE Main Bearing Bore Diameter Chart Inspect the main bearing bores for damage or abnormal wear. 1. Remove bearings and measure main bearing bore diameter after torquing main bearing cap bolts to 176 Nm (130 ft. lbs.). 2. Install the crankshaft main bearings and measure main bearing bore diameter with the main bolts tightened to 176 Nm (130 ft. lbs.) torque. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 3126 Crankshaft Main Journal Diameter Chart 3. Measure the diameter of the main journal at the locations shown. Calculate the average diameter for each side of the journal. 4. Calculate the main bearing journal to bearing clearance. Maximum clearance is 0.119 mm (0.00475 inch). If the crankshaft journal is within limits, replace the main bearings. If not within specifications, grind the crankshaft to next size and use oversize bearings. 5. Measure thrust distance at the No.6 position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair > Crankshaft Rear Oil Seal Retainer - Removal Crankshaft Seal Retainer: Service and Repair Crankshaft Rear Oil Seal Retainer - Removal REMOVAL 1. Disconnect the battery negative cables. 2. Raise vehicle on hoist. 3. Remove the oil pan drain plug and drain the engine oil. Re-install plug and torque to 50 Nm (44 ft. lbs.) torque. 4. Remove transmission and transfer case (if equipped) from vehicle. 5. Remove flywheel or torque converter drive plate. 6. Remove flywheel adapter plate. 7. Disconnect starter cables from starter motor. 8. Remove starter motor and transmission adapter plate assembly. 9. Remove four 4 oil pan rear bolts. Slide a feeler gauge between the seal retainer and oil pan gasket to break the seal. 10. Remove the six 6 retainer-to-block bolts (3). 11. Remove the rear seal retainer, and gasket (2). 12. Support the seal retainer and drive out the crankshaft seal with a hammer and suitable punch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair > Crankshaft Rear Oil Seal Retainer - Removal > Page 3131 Crankshaft Seal Retainer: Service and Repair Crankshaft Rear Oil Seal Retainer - Installation INSTALLATION 1. If using the old seal retainer, the crankshaft seal must be replaced. 2. Inspect oil pan gasket for nicks or cuts. If gasket is damaged, the oil pan must be removed and gasket must be replaced. Wipe oil pan gasket dry and apply light coating of RTV. 3. Using the retainer alignment/seal installation tool provided in the seal service kit, install the alignment tool into the retainer and install to the cylinder block, using a new gasket. Tighten the six (6) mounting bolts by hand. 4. The seal alignment tool is used to align rear cover properly. Starting with the center two bolts, tighten the retainer in a circular pattern to 10 Nm (89 in. lbs.). Remove the alignment tool. CAUTION: The seal lip and the sealing surface on the crankshaft must be free from all oil residue to prevent seal leaks. The crankshaft and seal surfaces must be completely dry when the seal is installed. Use a soap and water solution on outside diameter of seal to ease assembly. 5. Make sure the provided seal pilot (1) is installed into the new crankshaft seal (3). Use the alignment/installation tool and press the seal onto the crankshaft. Alternately drive the seal at the 12, 3, 6 and 9 o'clock positions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair > Crankshaft Rear Oil Seal Retainer - Removal > Page 3132 6. Remove the alignment tool and trim the retainer gasket (1) even with the oil pan mounting surface. 7. Remove the seal pilot. 8. Apply a small amount of Mopar(R) Silicone Rubber Adhesive Sealant to the oil pan rail T-joints. 9. Install the four (4) oil pan rear mounting bolts and torque to 28 Nm (21 ft. lbs.). 10. Install new rectangular ring seal for cam bore. 11. Install the flywheel housing and bolts. Torque bolts to 77 Nm (57 ft. lbs.). 12. Install the flywheel housing and bolts. Torque bolts to 77 Nm (57 ft. lbs.). NOTE: A new clamping ring must be used on early or late builds, automatic or manual. Do not reuse clamping ring. 13. Install the dual mass flywheel with crankshaft adapter. Tighten bolts to 137 Nm (101 ft. lbs.). 14. Install the starter motor. 15. Install the transmission and transfer case (if equipped). 16. Lower vehicle. 17. Fill the crankcase with new engine oil. 18. Connect the battery negative cables. 19. Start engine and check for oil leaks. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Description and Operation Crankshaft: Description and Operation DESCRIPTION The crankshaft is a forged steel, internally balanced unit. It is supported by seven main bearings, with position number six designated as the thrust journal. The crankshaft is held in place by main caps and 12 mm capscrews. The crankshaft also has internal cross drillings to supply the connecting rods with engine oil. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft Gear - Removal Crankshaft: Service and Repair Crankshaft Gear - Removal REMOVAL - GEAR 1. Remove the gear housing cover. 2. Split the gear and remove it from the crankshaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft Gear - Removal > Page 3138 Crankshaft: Service and Repair Crankshaft Gear - Installation INSTALLATION - GEAR 1. Remove all burrs and make sure the gear surface on the end of the crankshaft is smooth. 2. If removed, install a new alignment pin. Drive the pin in using a ball- peen hammer, leaving it protruding 1.0 mm (0.039 inch) to 1.5 mm (0.059 inch) above the crankshaft. WARNING: WEAR PROTECTIVE GLOVES TO PREVENT INJURY. CAUTION: DO NOT heat the gear longer than 45 minutes. 3. Heat the crankshaft gear for 45 minutes at a temperature of 149°C (300°F). Do not use torch, gear failure will occur. 4. Apply a thin coat of lubricant to the nose of the crankshaft. 5. Position the gear with the timing mark out and install it on the crankshaft using the alignment pin. Make sure the gear contacts the shoulder. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Engine Block Heater - Description Engine Block Heater: Description and Operation Engine Block Heater - Description DESCRIPTION WARNING: Do not operate engine unless block heater cord has been disconnected from power source and secured in place. The power cord must be secured in its retaining clips and routed away from exhaust manifolds and moving parts. An optional engine block heater is available with all models. The heater is equipped with a power cord. The cord is attached to an engine compartment component with tie-straps. The heater warms the engine providing easier engine starting and faster warm-up in low temperatures. The heater is mounted in a core hole of the engine cylinder block in place of a freeze plug with the heating element immersed in engine coolant. The 3.7L / 4.7L gas powered engines have the block heater located to the rear on the right side of the engine. The diesel engine has the block heater located on the right side of the engine below the exhaust manifold next to the oil cooler (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Engine Block Heater - Description > Page 3143 The 5.7L engine has the block heater (1) located on the left side of the engine below the exhaust manifold in the rear of the engine and is not immersed in engine coolant but makes direct contact with the block. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Engine Block Heater - Description > Page 3144 Engine Block Heater: Description and Operation Engine Block Heater - Operation OPERATION The heater warms the engine coolant providing easier engine starting and faster warm-up in low temperatures. Connecting the power cord to a grounded 110-120 volt AC electrical outlet with a grounded three wire extension cord provides the electricity needed to heat the element. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 3145 Engine Block Heater: Testing and Inspection ENGINE BLOCK HEATER If the unit does not operate, possible causes can be either the power cord or the heater element. Test the power cord for continuity with a 110-volt voltmeter or 110-volt test light. Test heater element continuity with an ohmmeter or a 12-volt test light. CAUTION: To prevent damage, the power cord must be secured in it's retainer clips and away from any components that may cause abrasion or damage, such as linkages, exhaust components, etc. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Engine Block Heater - Removal Engine Block Heater: Service and Repair Engine Block Heater - Removal 5.9L/6.7L DIESEL 1. Disconnect the battery negative cables. 2. Drain coolant from radiator and cylinder block. 3. Unscrew the power cord retaining cap and disconnect cord from heater element. 4. Using a suitable size socket, loosen and remove the block heater element. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Engine Block Heater - Removal > Page 3148 Engine Block Heater: Service and Repair Engine Block Heater - Installation 5.9L/6.7L DIESEL 1. Clean and inspect the threads in the cylinder block and heater element. 2. Coat heater element threads with Mopar(R) Thread Sealer with Teflon. 3. Screw block heater (1) into cylinder block and tighten to 75 Nm (55 ft. lbs.). 4. Connect block heater cord and tighten retaining cap. 5. Fill cooling system with recommended coolant. 6. Start and warm the engine. 7. Check block heater for leaks. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft damper Torque bolts to ...................................................................................................................... 40 Nm (30 ft. lbs.) plus an additional 60° Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair > Procedures Harmonic Balancer - Crankshaft Pulley: Procedures INSPECTION NOTE: The Crankshaft damper is of viscous design and the speed indicator is incorporated into the crankshaft damper. 1. Inspect the damper hub for cracks and replace if any are found. 2. If the crankshaft damper is leaking fluid, discard and replace the crankshaft damper. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair > Procedures > Page 3154 Harmonic Balancer - Crankshaft Pulley: Removal and Replacement Vibration Damper - Removal REMOVAL 1. Remove the accessory drive belt. 2. Remove the four (4) damper to crankshaft bolts and remove damper. Vibration Damper - Installation INSTALLATION 1. Install the crankshaft damper and bolts. Tighten bolts to 40 Nm (30 ft. lbs.) torque, plus an additional 60°. NOTE: The damper must be installed so the hole is located over the dowel pin. 2. Install the accessory drive belt. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Pistons Pistons Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 3158 Piston: Description and Operation DESCRIPTION PISTONS The piston is constructed of aluminum and is gravity cast, free floating design. The piston incorporates a centrally located high swirl combustion bowl, and utilizes a "keystone" style top compression ring, and a "Tapered Face" intermediate ring, for superior cylinder wall scraping. Piston cooling nozzles cool the piston and pin with engine oil supplied by the crankshaft main journals. All pistons are gallery cooled and utilize J-jet piston cooling nozzles. Pistons are directional in order to provide clearance to piston cooling nozzles. CONNECTING RODS The connecting rods are a split angle design. They have a pressed-in-place wrist pin bushing that is lubricated by piston cooling nozzle oil spray. Machined connecting rods are no longer used in the diesel engine. Do not install machined connecting rods into an engine that has fractured split connecting rods. Fractured split connecting rods are first manufactured as a single piece and then fractured into two pieces. Fractured split connecting rods can be identified by a rough and irregular surface at the connecting rod split face. To properly assemble the rod cap to the connecting rod, the bearing tangs on the connecting rod and cap must be located on the same side of the rod. The long end of the connecting rod must be assembled on the intake or camshaft side of the engine. Each matched fractured split connecting rod and cap is an assembly and are not interchangeable. If a connecting rod or cap is damaged, the entire assembly must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures Piston: Procedures Piston and Connecting Rod - Cleaning CLEANING CAUTION: DO NOT use bead blast to clean the pistons. DO NOT clean the pistons and rods in an acid tank. PISTON Clean the pistons and pins in a suitable solvent, rinse in hot water and blow dry with compressed air. Soaking the pistons over night will loosen most of the carbon build up. De-carbon the ring grooves with a broken piston ring and again clean the pistons in solvent. Rinse in hot water and blow dry with compressed air. CONNECTING ROD Clean the connecting rods in a suitable solvent, rinse in hot water and blow dry with compressed air. Piston and Connecting Rod - Inspection PISTONS Inspect the pistons for damage and excessive wear. Check top of the piston, ring grooves, skirt and pin bore. Measure the piston skirt diameter. If the piston is out of limits, replace the piston. The upper groove only needs to be inspected for damage. Use a new piston ring (2) to measure the clearance in the intermediate ring groove. Minimum clearance is 0.045 mm (0.0018 inch), maximum clearance is 0.095 mm (.0037 inch). If the clearance of the intermediate ring exceeds specifications, replace the piston (3). Use a new oil ring to measure the clearance in the oil groove. Minimum clearance is 0.040 mm (0.0016 inch), maximum clearance is 0.085 mm (.0033 inch). If the clearance exceeds specifications, replace the piston. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 3161 Measure the pin bore (2). The maximum diameter is 40.012 mm (1.5753 inch), Minimum is 40.006 mm (1.575 inch). If the bore is over limits, replace the piston (1). Inspect the piston pin for nicks, gouges and excessive wear. Measure the pin diameter (1). The minimum diameter is 39.990 mm (1.5744 inch), maximum 40.003 mm (1.5749 inch). If the diameter is out of limits, replace the pin (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 3162 Piston: Removal and Replacement Piston and Connecting Rod - Removal REMOVAL 1. Disconnect the battery cables. 2. Remove the cylinder head. 3. Remove the oil pan and suction tube. 4. Remove bolts and the block stiffener. 5. Using Miller Tool 7471-B crankshaft barring tool, rotate the crankshaft so all of the pistons are below TDC. 6. Before removing the piston(s) from the bore(s): a. Remove any carbon ridge formations or deposits at the top of the bore with a dull scraper or soft wire brush. b. If cylinder bore wear ridges are found, use a ridge reamer to cut the ridge from the bore. DO NOT remove more metal than necessary to remove the ridge. 7. Remove the J-jet cooling nozzles. NOTE: If cylinders have ridges, the cylinders are oversize and will more than likely need boring. 8. Using a hammer and steel stamp, stamp the cylinder number in the top of each piston. The front of the piston is identified by a stamping on the top of the piston. DO NOT stamp in the outside 5 mm (.197 in.) of the piston diameter. DO NOT stamp over the piston pin. 9. Mark the connecting rod and cap with the corresponding cylinder numbers. 10. Remove the connecting rod bolts and rod caps. Use care so the cylinder bores and connecting rods are not damaged. 11. Use a hammer handle or similar object to push the piston and connecting rod through the cylinder bore. 12. Store the piston/rod assemblies in a rack. Piston and Connecting Rod - Installation INSTALLATION 1. Lubricate the cylinder bores with clean engine oil. 2. Generously lubricate the rings and piston skirts with clean engine oil. 3. Orientate the rings on the piston. 4. Compress the rings using a piston ring compressor tool (1). If using a strap-type ring compressor, make sure the inside end of the strap does not hook on a ring gap and break the ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 3163 5. Bar the crankshaft so the rod journal for the piston to be installed is at BDC (Bottom Dead Center). 6. Make sure the front of the piston is oriented properly according to the marking on the top of the piston and the connecting rod is oriented properly. 7. Position the piston and rod assembly into the cylinder bore with the front of the piston oriented properly according to the stamping in the top of the piston. Use care when you install the piston and connecting rod so the cylinder bore is not damaged. The long side of the connecting rod must be installed on the exhaust side of the engine. 8. Push the piston into the bore until the top of the piston is approximately 50 mm (2 inch) below the top of the block. Carefully pull the connecting rod onto the crankshaft journal. 9. Use clean engine oil to lubricate the threads and under the heads of the connecting rod bolts. 10. For fractured/split type connecting rods, the long end of the rod must be installed away from the intake side of the engine. a. The connecting rod split/face must face toward the same side as the piston notch feature on the skirt. The split face will face toward the exhaust side of the engine if properly installed. 11. Install the rod cap and bolts to the connecting rod. Tighten the connecting rod bolts evenly in 3 steps. - Tighten the bolts to 30 Nm (22 ft. lbs.) torque. - Tighten the bolts to 60 Nm (44 ft. lbs.) torque. - Rotate 60° clockwise. 12. The crankshaft must rotate freely. Check for freedom of rotation as the caps are installed. If the crankshaft does not rotate freely, check the installation of the rod bearing and the bearing size. 13. Measure the side clearance between the connecting rod and the crankshaft. DO NOT measure the clearance between the cap and crankshaft. 14. Install J-jet piston cooling nozzles. 15. Install block stiffener. Torque to 43 Nm (32 ft. lbs.). 16. Install the suction tube and oil pan. 17. Install the cylinder head onto the engine. 18. Install a new filter and fill the crankcase with new engine oil.Prefill the filter with clean oil. 19. Connect the battery negative cables and start engine. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Piston Pins Piston Pins Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston Rings Piston Rings Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 3170 Piston Ring: Service and Repair PISTON RING FITTING 1. Determine the piston diameter and obtain the appropriate ring set. The piston rings can be identified as shown. 2. Position each ring in the cylinder and use a piston (1) to square it with the bore at a depth (3) of 89.0 mm (3.5 inch). Piston Ring Gap Chart 3. Use a feeler gauge to measure the piston ring gap. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 3171 4. The top surface of all of the compression rings are identified with the word TOP or the supplier's MARK. Assemble the rings with the word TOP or the supplier's MARK up. 5. Position the oil ring expander (2) in the oil control ring (1) groove (bottom groove). NOTE: There is no (TOP) mark on the oil ring. 6. Install the oil control ring (1) with the end gap OPPOSITE the ends on the expander. 7. Install the intermediate piston ring in the second groove. 8. Install the top piston ring in the top groove. 9. Position the rings as shown. - Install top and second compression rings on piston with ring gaps 180° apart. - Install oil control ring with ring gap 90° from top and second ring. Do not position gaps over wrist pin hole. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments VALVE LASH ADJUSTMENT AND VERIFICATION NOTE: To obtain accurate readings, valve lash measurements AND adjustments should only be performed when the engine coolant temperature is less than 60°C (140°F). The 24-valve overhead system is a "low-maintenance" design. Routine adjustments are no longer necessary, however, measurement should still take place when troubleshooting performance problems, or upon completion of a repair that includes removal and installation of the valve train components or injectors. 1. Disconnect battery negative cables. 2. Remove cylinder head cover. 3. Using the crankshaft barring tool #7471-B, rotate crankshaft to align damper TDC mark to 12:00 o'clock position. a. If both number one cylinder rocker levers are loose, continue to next step. b. If both number one cylinder rocker levers are not loose, rotate crankshaft 360 degrees. 4. With the engine in this position, valve lash can be measured at the following rocker arms: INTAKE 1-2-4 / EXHAUST 1-3-5. Measure the valve lash by inserting a feeler gauge between the rocker arm socket and crosshead. Refer to VALVE LASH LIMIT CHART for the correct specifications. If the measurement falls within the limits, adjustment/resetting is not necessary. If measurement finds the lash outside of the limits, adjustment/resetting is required. Valve Lash Limit Chart Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Adjustments > Page 3176 5. If adjustment/resetting is required, loosen the lock nut on rocker arms and turn the adjusting screw until the desired lash is obtained: - INTAKE 0.254 mm (0.010 in.) - EXHAUST 0.660 mm (0.026 in.) Tighten the lock nut to 24 Nm (18 ft. lbs.) and recheck the valve lash. 6. Using the crankshaft barring tool, rotate the crankshaft one revolution (360°) to align the damper TDC mark to the 12 o'clock position. 7. With the engine in this position, valve lash can be measured at the remaining rocker arms: INTAKE 3-5-6 / EXHAUST 2-4-6. Use the same method as above for determining whether adjustment is necessary, and adjust those that are found to be outside of the limits. 8. Install the cylinder head cover. 9. Connect the battery negative cables. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Description and Operation Rocker Arm Assembly: Description and Operation DESCRIPTION The unique intake and exhaust rocker arms have their own rocker shafts and are lubricated by passages intersecting the cylinder block main oil rifle. Crossheads are used, which allow each rocker arm to operate two valves. The solid push rods are hardened at the rocker arm and tappet contact areas for superior strength and durability. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures Rocker Arm Assembly: Procedures Cleaning CLEANING Clean all components in a suitable solvent. If necessary, use a wire brush or wheel to remove stubborn deposits. Rinse in hot water and blow dry with compressed air. Inspect oil passages in rocker arms and pedestals. Apply compressed air to lubrication orifices to purge contaminants. Inspection INSPECTION Rocker Arms 1. Remove rocker shaft and inspect for cracks and excessive wear in the bore or shaft. Remove socket and inspect ball insert and socket for signs of wear. Replace retainer if necessary. Measure the rocker arm bore and shaft. Push Rods Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 3182 Inspect the push rod ball and socket for signs of scoring. Check for cracks where the ball and the socket are pressed into the tube. Roll the push rod on a flat work surface with the socket end hanging off the edge. Replace any push rod that appears to be bent. Crossheads Inspect the crossheads for cracks and/or excessive wear on rocker lever and valve tip mating surfaces. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 3183 Rocker Arm Assembly: Removal and Replacement Removal REMOVAL 1. Disconnect the battery negative cables. 2. Remove cylinder head cover. 3. Remove the rocker arm/pedestal fasteners and remove rocker arm (1) and pedestal (2) from cylinder head. Mark the arms and pedestals so they can be installed in their original position. CAUTION: When removing the rocker arms, the sockets may come loose and fall into the engine. Make sure they stay with the arm upon removal/installation. 4. Lift the push rod(s) up and out of the engine. Mark them so they can be installed in their original position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 3184 NOTE: The #5 cylinder intake and exhaust, and #6 cylinder intake and exhaust push rods must be raised through the provided cowl panel access holes. 5. Lift the crossheads off of the valve stems. Mark them so they can be installed in their original position. Installation INSTALLATION 1. If previously removed, install the push rods in their original location. Verify that they are seated in the tappets. 2. Lubricate the valve tips and install the crossheads in their original locations. 3. Lubricate the crossheads and push rod sockets and install the rocker arms and pedestals in their original locations. Tighten bolts to 36 Nm (27 ft. lbs.) torque. 4. Verify valve lash adjustment. 5. Install cylinder head cover. 6. Connect battery negative cables. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Procedures Valve Cover: Procedures Cleaning CLEANING Using a suitable solvent, Clean and dry gasket mating surfaces on cylinder head and rocker housing. Wipe gasket dry and inspect for re-use. Inspection INSPECTION The cylinder head cover gasket and rocker housing gasket, are reusable. However, should cracks, nicks, or tears be present in the rubber/silicone construction, the defective components should be replaced. Also replace gasket if it is no longer flexible. Inspect cylinder head cover rubber isolated capscrews for cracks, nicks, or tears.Do not reuse gasket if it has been removed from the groove in the rocker housing or cylinder head cover. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Procedures > Page 3189 Valve Cover: Removal and Replacement Rocker Housing ROCKER HOUSING 1. Remove the breather cover and the cylinder head cover. 2. Remove injector harness nuts from injectors. 3. Remove cylinder head cover gasket. 4. Remove rocker housing bolts. 5. Remove rocker housing and gasket. Cylinder Head Cover CYLINDER HEAD COVER 1. Disconnect both negative battery cables. 2. Remove the Breather Cover Capscrews (8-M6 screws). 3. Remove the CCV breather and filter cover (3). 4. Disconnect CCV Tube (4) at the CDR valve (one spring clamp) and remove 10mm nut from tube bracket at EGR Cooler support bracket stud. 5. Disconnect CDR valve Tube to Air Inlet Silencer (Spring Clamp). 6. Disconnect CDR/Valve cover pressure sensor connector. 7. Remove Oil fill cap. 8. Remove CCV oil drains (2) from valve cover (2 hoses). 9. Disconnect both injector harness connectors (1). 10. Remove six (6) valve cover capscrews (10mm). 11. Remove the valve cover. 12. Loosen injector wire nuts from the valve cover gasket (8mm). 13. Remove gasket. Cylinder Head Cover Gasket CYLINDER HEAD COVER GASKET Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Procedures > Page 3190 1. Remove cylinder head cover. 2. Disconnect injector harness connectors (3) at cylinder head cover gasket. 3. Remove injector solenoid nuts (1) at injectors. 4. Remove cylinder head cover gasket (2). Rocker Housing ROCKER HOUSING 1. Inspect rocker housing gasket for cuts, nicks, or tears. Replace if damaged or if gasket has come out of groove. 2. Inspect rocker housing gasket for proper installation in groove. Gasket bead must be centered in groove. A gasket bead that is tilted to the side will cause an oil leak. CAUTION: When installing rocker housing onto cylinder head, do not slide housing from side to side, The gasket could fall out or be damaged. 3. Install the rocker housing. Carefully guide the rocker housing evenly down onto the cylinder head. 4. Install rocker housing bolts and tighten finger tight. 5. Torque bolts, working from center out, to 24 Nm (18 ft. lbs.). Cylinder Head Cover CYLINDER HEAD COVER Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Procedures > Page 3191 NOTE: Gasket must be completely dry and free of oil before installation. 1. Wipe oil from the valve cover gasket, rocker box, and valve cover. 2. Inspect valve cover gasket for tears, or splits. Replace if necessary. 3. Install the valve cover gasket on the rocker box. 4. Install the injector nuts (8 mm) to injector studs. Torque to 1.25 Nm (11 in. lbs.). 5. Install valve cover and valve cover capscrews (10mm). tighten from center out. Torque to 24 Nm (18 ft. lbs.). 6. Install the valve cover CCV drain hoses (2). 7. Remove any oil from the CCV seal area and install the CCV filter. 8. Install the CCV cover and capscrews (6mm). Torque to 10 Nm (89 in. lbs.). 9. Connect CDR valve tube to Air Inlet Silencer (spring clamps). 10. Connect the Breather/Valve Cover Pressure sensor. 11. Install oil fill cap. 12. Connect the batteries. 13. Start the vehicle and check for leaks. Cylinder Head Cover Gasket CYLINDER HEAD COVER GASKET Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Procedures > Page 3192 1. Clean oil from cylinder head cover gasket 2. Inspect cylinder head cover gasket for cuts or damage. Replace if damaged. 3. Place cylinder head cover gasket on top of rocker housing (2). 4. Install injector solenoid nuts (1) at injectors. Torque to 1.25 Nm (11 in. lbs.). 5. Connect injector harness connectors (3) at cylinder head cover gasket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair Valve Spring: Service and Repair VALVES, GUIDES AND SPRINGS REMOVAL 1. Remove cylinder head. 2. Support cylinder head on stands, or install head bolts upside down (through combustion surface side) to protect injector tips from damage from work bench. 3. Install the valve spring compressor mounting base (1) as shown. 4. Install the compressor top plate, washer, and nut. Using a suitable wrench, tighten the nut (clockwise) to compress the valve springs and remove the locks. 5. Rotate the compressor nut counter-clockwise to relieve tension on the springs. Remove the spring compressor (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 3196 6. Remove the retainers (5), springs (4), valve seals (3) (if necessary), and valves (2). Arrange or number all components so they can be installed in their original locations. 7. Repeat the procedure on all cylinders to be serviced. CLEANING Clean the valve stems with crocus cloth or a Scotch-Brite(TM) pad. Remove carbon with a soft wire brush. Clean valves, springs, retainers, and valve retaining locks in a suitable solvent. Rinse in hot water and blow dry with compressed air. INSPECTION Visually inspect the valves for abnormal wear on the heads, stems, and tips. Replace any valve that is worn out or bent. Measure the valve stem diameter in three places as shown. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 3197 Valve Guide Bore Specifications Measure the cylinder head valve guide bore. Measure valve margin (rim thickness). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 3198 Measure the valve spring free length and maximum inclination. Test valve spring force with tool C-647 (1). Specification 72.0 - 80.7 lbs. when compressed to 35.33 mm (1.39 in.). INSTALLATION 1. Install new valve seals. The yellow seals are for the intake valves and the green seals are for the exhaust valves. 2. Install the valves in their original position. The exhaust valves are identified by a dimple on the valve head. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 3199 3. Install the valve (2), springs (4), and retainer (5). 4. Install the valve spring compressor tool 8319-A (1) as shown. 5. Compress the valve springs and install the valve retaining locks. 6. Remove the compressor and repeat the procedure on the remaining cylinders. 7. Install new o-ring and sealing washer on injector. 8. Lubricate o-ring and injector bore. 9. Verify sealing washer (shim) was removed with old injector. 10. Install injector. 11. Install the cylinder head. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Description and Operation Valve: Description and Operation DESCRIPTION The intake valves (1) are made of heat resistant steel, and have chrome plated stems to prevent scuffing. The exhaust valves are made of iron alloys (2). The intake and exhaust valves are both similar in head diameter and overall length, but they have unique face angles which makes them non-interchangeable. The valves are distinguished by unique dimples on the exhaust valve head (2). The exhaust valve springs are made from high strength, chrome silicon steel. The exhaust valve springs are also exhaust brake compatible. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal - Valve Springs Valve: Service and Repair Removal - Valve Springs REMOVAL - VALVE SPRINGS 1. Disconnect the battery negative cables. 2. Remove the cylinder head cover. 3. Disconnect the injector harness connectors at cylinder head cover gasket. Remove all injector solenoid nuts. Remove cylinder head cover gasket. 4. Remove injector(s) for cylinder(s) to be serviced. 5. Remove the rocker housing. 6. Remove the rocker arms and crossheads from the cylinder(s) to be serviced. Mark each component so they can be installed in their original position. 7. Using the crankshaft barring tool # 7471-B (2), rotate the engine to position the damper mark in the 12 o'clock position. At this engine position, cylinders #1 and #6 can be serviced. 8. Remove the accessory drive belt. 9. With the damper TDC mark in the 12 o'clock position, add a paint mark anywhere on the gear housing cover next to the crankshaft damper. Place another mark on the vibration damper in alignment with the mark you just made on the cover. 10. Divide the crankshaft damper into three equally sized segments as follows: a. Using a tape measure, measure the circumference of the crankshaft damper and divide the measurement by three (3). b. Measure that distance in a counterclockwise direction from the first balancer mark and place another mark on the balancer. c. From the second damper mark, again measure in a counterclockwise direction and place a mark on the damper at the same distance you measured when placing the second damper mark. The damper should now be marked in three equally spaced locations and the damper TDC mark should be in the 12 o'clock position. d. Remove injectors, fuel lines, and high pressure connectors for every cylinder that requires repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal - Valve Springs > Page 3205 11. Compress the valve springs at cylinders. #1 and #6 as follows: a. Install the valve spring compressor mounting base as shown in. b. Install the top plate, washer, and nut. Using a suitable wrench tighten the nut (clockwise) to compress the valve springs and remove the collets. c. Rotate the compressor nut counterclockwise to relieve tension on springs. Remove spring compressor. d. Remove and replace retainers, springs, and seals as necessary. e. Do not rotate the engine until the springs and retainers are reinstalled. f. Install seals, springs and retainers. Install spring compressor, compress valve springs and install the collets. g. Release the spring tension and remove the compressor. Verify that the collets are seated by tapping on the valve stem with a plastic hammer. 12. Using the crankshaft barring tool (2), rotate the engine until the next crankshaft damper paint mark aligns with the mark you placed on the cover. In this position, cylinders #2 and #5 can be serviced. 13. Repeat the valve spring compressing procedure previously performed and service the retainers, springs, and seals as necessary. 14. Using the crankshaft barring tool, rotate the engine until the next crankshaft damper paint mark aligns with the mark you placed on the cover. In this position, cylinders #3 and #4 can be serviced. 15. Repeat the spring compressing procedure previously performed and service the retainers, springs, and seals as necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal - Valve Springs > Page 3206 Valve: Service and Repair Installation INSTALLATION 1. Install rocker housing. 2. Install fuel injectors and high pressure fuel lines. 3. Lubricate the valve tips and install the crossheads in their original locations. 4. Lubricate the crossheads and push rod sockets and install the rocker arms and pedestals in their original locations. Tighten bolts to 36 Nm (27 ft. lbs.) torque. 5. Verify valve lash adjustment. 6. Install cylinder head cover gasket onto rocker housing. 7. Install injector solenoid nuts. 8. Connect injector harness connectors. 9. Install cylinder head cover. 10. Connect battery negative cables. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal - Valve Springs > Page 3207 Valve: Service and Repair Valves, Guides And Springs VALVES, GUIDES AND SPRINGS REMOVAL 1. Remove cylinder head. 2. Support cylinder head on stands, or install head bolts upside down (through combustion surface side) to protect injector tips from damage from work bench. 3. Install the valve spring compressor mounting base (1) as shown. 4. Install the compressor top plate, washer, and nut. Using a suitable wrench, tighten the nut (clockwise) to compress the valve springs and remove the locks. 5. Rotate the compressor nut counter-clockwise to relieve tension on the springs. Remove the spring compressor (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal - Valve Springs > Page 3208 6. Remove the retainers (5), springs (4), valve seals (3) (if necessary), and valves (2). Arrange or number all components so they can be installed in their original locations. 7. Repeat the procedure on all cylinders to be serviced. CLEANING Clean the valve stems with crocus cloth or a Scotch-Brite(TM) pad. Remove carbon with a soft wire brush. Clean valves, springs, retainers, and valve retaining locks in a suitable solvent. Rinse in hot water and blow dry with compressed air. INSPECTION Visually inspect the valves for abnormal wear on the heads, stems, and tips. Replace any valve that is worn out or bent. Measure the valve stem diameter in three places as shown. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal - Valve Springs > Page 3209 Valve Guide Bore Specifications Measure the cylinder head valve guide bore. Measure valve margin (rim thickness). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal - Valve Springs > Page 3210 Measure the valve spring free length and maximum inclination. Test valve spring force with tool C-647 (1). Specification 72.0 - 80.7 lbs. when compressed to 35.33 mm (1.39 in.). INSTALLATION 1. Install new valve seals. The yellow seals are for the intake valves and the green seals are for the exhaust valves. 2. Install the valves in their original position. The exhaust valves are identified by a dimple on the valve head. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal - Valve Springs > Page 3211 3. Install the valve (2), springs (4), and retainer (5). 4. Install the valve spring compressor tool 8319-A (1) as shown. 5. Compress the valve springs and install the valve retaining locks. 6. Remove the compressor and repeat the procedure on the remaining cylinders. 7. Install new o-ring and sealing washer on injector. 8. Lubricate o-ring and injector bore. 9. Verify sealing washer (shim) was removed with old injector. 10. Install injector. 11. Install the cylinder head. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams With A/C 1- Idler Pulley 2- Accessory Drive Belt 3- Power Steering Pulley 4- Radiator Fan Pulley 5Crankshaft Pulley 6- A/C Compressor Pulley 7- Accessory Drive Belt Tensioner 8- Generator 9Water Pump Pulley Without A/C Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 3216 1- Idler Pulley 2- Accessory Drive Belt 3- Power Steering Pulley 4- Radiator Fan Pulley 5Crankshaft Pulley 6- Accessory Drive Belt Tensioner 7- Generator 8- Water Pump Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 3217 Drive Belt: Description and Operation DESCRIPTION The accessory drive belt is a serpentine type belt. Satisfactory performance of these belts depends on belt condition and proper belt tension. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 3218 Drive Belt: Testing and Inspection DIAGNOSIS AND TESTING VISUAL DIAGNOSIS NOTE: Diesel Engine - If a belt is broken or frayed, inspect engine speed sensor (located near the crankshaft damper) for damage. When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib , are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing. Refer to ACCESSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis. NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 3219 Accessory Drive Belt Diagnosis Chart (Part 1) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 3220 Accessory Drive Belt Diagnosis Chart (Part 2) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Procedures Drive Belt: Procedures CLEANING Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and coolants before installing the drive belt. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Procedures > Page 3223 Drive Belt: Removal and Replacement Removal 5.9L/6.7L DIESEL Belt Routing-Diesel Engine Without A/C 1. A 1/2 inch square hole is provided in the automatic belt tensioner. Attach a 1/2 inch drive-long handle ratchet to this hole. BELT ROUTING-DIESEL WITH A/C 2. Rotate ratchet and tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt. 3. Remove belt from water pump pulley first. 4. Remove belt from vehicle. Installation 5.9L/6.7L DIESEL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Procedures > Page 3224 Belt Routing - DIESEL WITH A/C CAUTION: When installing the accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. 1. Position drive belt over all pulleys except water pump pulley. 2. Attach a 1/2 inch ratchet to tensioner. Belt Routing - DIESEL WITHOUT A/C 3. Rotate ratchet and belt tensioner clockwise. Place belt over water pump pulley. Let tensioner rotate back into place. Remove ratchet. Be sure belt is properly seated on all pulleys. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Description and Operation > Description Drive Belt Tensioner: Description and Operation Description DESCRIPTION Correct drive belt tension is required to ensure optimum performance of the belt driven engine accessories. If specified tension is not maintained, belt slippage may cause; engine overheating, lack of power steering assist, loss of air conditioning capacity, reduced generator output rate, and greatly reduced belt life. It is not necessary to adjust belt tension. All engines are equipped with an automatic belt tensioner. The tensioner maintains correct belt tension at all times. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Description and Operation > Description > Page 3229 Drive Belt Tensioner: Description and Operation Operation OPERATION The automatic belt tensioner maintains belt tension by using internal spring pressure, a pivoting arm and pulley to press against the drive belt. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Removal Drive Belt Tensioner: Service and Repair Removal 5.9L/6.7L DIESEL WARNING: Because of high spring pressure, do not attempt to disassemble automatic tensioner. Unit is serviced as an assembly. 1. Remove accessory drive belt. 2. Remove tensioner mounting bolt and remove tensioner (7). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Removal > Page 3232 Drive Belt Tensioner: Service and Repair Installation 5.9L/6.7L DIESEL 1. Install tensioner assembly (7) to water inlet bracket. A dowel is located on back of tensioner. Align this dowel to hole in tensioner mounting bracket. Tighten bolt to 43 Nm (32 ft. lbs.) torque. 2. Install drive belt. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount Engine Mount: Service and Repair Front Mount Removal REMOVAL CAUTION: If replacing a engine mount / bracket, be certain to inspect all other engine mounts / brackets in the system. Failure to follow this caution may result in damage to the vehicle. 1. Disconnect the battery negative cables. 2. Remove the viscous fan/drive assembly. 3. Raise vehicle on hoist. 4. Install engine support fixture tool #8534 and steel bracket tool #8534A 5. Loosen the thru-bolt and nut. 6. Lift the engine SLIGHTLY and remove the insulator to block bolts. 7. Remove the RH mount (2) from the engine. 8. Remove the LH insulator (2) from the vehicle. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 3237 CAUTION: If replacing a engine mount / bracket, be certain to inspect all other engine mounts / brackets in the system. Failure to follow this caution may result in damage to the vehicle. 1. With engine raised SLIGHTLY, position the LH insulator (2) to the mount. Install the bolts and torque to specification. 2. With engine raised SLIGHTLY, position the RH insulator (2) to the mount. Install the bolts and torque to specification. 3. Lower the engine using tool #8534, while guiding the mount and thru-bolt into the frame mounted support cushion brackets. 4. Install the thru bolt nut and tighten the nut to 95 Nm (70 ft. lbs.) torque. 5. Remove the engine support fixture tool #8534. 6. Lower the vehicle. 7. Install the viscous fan/drive assembly. 8. Connect the battery negative cables. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 3238 Engine Mount: Service and Repair Rear Mount Removal REMOVAL CAUTION: If replacing a engine mount / bracket, be certain to inspect all other engine mounts / brackets in the system. Failure to follow this caution may result in damage to the vehicle. 1. Raise the vehicle on a hoist. 2. Position a transmission jack in place. 3. Remove support cushion stud nuts (6). 4. Raise rear of transmission until cushion studs (6) clear frame. 5. Remove the nuts holding the support cushion (5) to the transmission support bracket (8). 6. Remove support cushion (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 3239 7. Remove the bolts (3) holding the transmission support to the bracket (4). 8. Remove the bolts (7) holding the transmission support to the transmission. 9. Remove the transmission support (8). 10. Remove the nuts (1) from the transmission bracket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 3240 11. Remove the bracket (3) from the transmission. Installation INSTALLATION CAUTION: If replacing a engine mount / bracket, be certain to inspect all other engine mounts / brackets in the system. Failure to follow this caution may result in damage to the vehicle. 1. If removed, position the brackets to the transmission. Install attaching fasteners (1, 2), Do not tighten at this time.. 2. Position support cushion (5) to transmission support bracket (3). Install stud nuts (4) and tighten to 61 Nm (45 ft. lbs.) torque. 3. Position assembled support cushion (5) and bracket (3) to transmission. 4. Install the support bracket bolt (7) and tighten to 54 Nm (40 ft. lbs.) torque. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 3241 5. Install the support bracket bolts (3) and tighten to 50 Nm (37 ft. lbs.) torque. 6. Torque the bracket to transmission nuts (11) to 30 Nm (22 ft. lbs.) torque. 7. Using the transmission jack, lower the transmission and support cushion (5) onto the crossmember. 8. Install the support cushion nuts (6) and tighten to 61 Nm (45 ft. lbs.) torque. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 3242 9. Remove the transmission jack. 10. Lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure Oil Pressure Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 3247 Engine Oil Pressure: Testing and Inspection DIAGNOSIS AND TESTING-ENGINE OIL PRESSURE 1. Remove the 1/8 npt plug from the top of the oil filter housing. 2. Install Oil Pressure Line and Gauge Tool C-3292 with a suitable adapter. 3. Start engine and warm to operating temperature. 4. Record engine oil pressure and compare with engine oil pressure chart. CAUTION: If engine oil pressure is zero at idle, DO NOT RUN THE ENGINE. If minimum engine oil pressure is below these ranges, Refer to ENGINE - TESTING. 5. Remove oil pressure gauge and install the 1/8 npt plug. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Engine Oil: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 3252 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil with Filter ............................................................................................................................ ................................................. 11.4Liters (12.0 Qt) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 3255 Engine Oil: Fluid Type Specifications ENGINE OIL ........................................................................................................................................ ........................................................ Mopar 15W-40 Low ash diesel engine oil is REQUIRED for the 6.7L engine. NOTE: Use only Low Ash Diesel Engine Oil meeting standard MIL-2104C or API Classification CJ or higher that meets CES 20081 Standards. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 3256 Engine Oil: Testing and Inspection ENGINE OIL LEVEL CAUTION: Do not overfill crankcase with engine oil, oil foaming and oil pressure loss can result. To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable oil level is in the SAFE RANGE (3) on the engine oil dipstick. NOTE: The best time to check the engine oil level is after the engine is at operating temperature and has been turned off (not running) for 30 minutes. 1. Position vehicle on level surface. 2. With engine OFF, allow approximately 30 minutes for oil to settle to bottom of crankcase, remove engine oil dipstick. 3. Wipe dipstick clean. 4. Replace dipstick and verify it is seated in the tube. 5. Remove dipstick, with handle held above the tip, take oil level reading. 6. Add oil only if level is below the SAFE RANGE area on the dipstick. 7. Replace dipstick. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 3257 Engine Oil: Service and Repair ENGINE OIL SERVICE WARNING: Hot oil can cause personal injury. NOTE: Change engine oil and filter at intervals specified in the owner's manual. 1. Operate the engine until the water temperature reaches 60°C (140°F). Shut the engine off. 2. Use a container that can hold at least 14 liters (15 quarts) to hold the used oil. Remove the oil drain plug and drain the used engine oil into the container. 3. Always check the condition of the used oil. This can give you an indication of engine problems that might exist. - Thin, black oil indicates fuel dilution. - Milky discoloration indicates coolant dilution. 4. Clean the area around the oil filter head. Remove the filter. 5. Install new oil filter. 6. Clean the drain plug and the sealing surface of the pan. Check the condition of the threads and sealing surface on the oil pan and drain plug. 7. Install the drain plug. Tighten the plug to 50 Nm (37 ft. lbs.) torque. 8. Use only High-Quality Low Ash Multi-Viscosity lubricating oil in the Cummins Turbo Diesel engine. 9. Fill the engine with the correct grade of new oil. 10. Start the engine and operate it at idle for several minutes. Check for leaks at the filter and drain plug. 11. Stop engine. Wait 30 minutes to allow the oil to drain back to the pan and check the level again. USED ENGINE OIL DISPOSAL Care should be exercised when disposing of used engine oil after it has been drained from a vehicle's engine. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Control Valve > Component Information > Service and Repair > Procedures Engine Oil Control Valve: Procedures Cleaning CLEANING 1. Clean the regulator spring and plunger with a suitable solvent and blow dry with compressed air. If the plunger bore requires cleaning, it is necessary to remove the oil filter head to avoid getting debris into the engine. Inspection INSPECTION Inspect the plunger and plunger bore for cracks and excessive wear. Polished surfaces are acceptable. Verify that the plunger moves freely in the bore. Check the spring for height and load limitations. Replace the spring if out of limits shown in the figure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Control Valve > Component Information > Service and Repair > Procedures > Page 3262 Engine Oil Control Valve: Removal and Replacement Removal REMOVAL 1. Disconnect the battery negative cables. 2. Remove the threaded plug (2), spring (4) and valve (5). Insert a finger or a seal pick to lift the plunger from the bore. NOTE: If the plunger is stuck in the bore, it will be necessary to remove the filter head. Installation INSTALLATION 1. Install the plunger, spring, and plug as shown in. Tighten the plug to 80 Nm (59 ft. lbs.) torque. 2. Connect the battery negative cables. 3. Start the engine and verify that it has oil pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Procedures Oil Cooler: Procedures CLEANING AND INSPECTION Clean the sealing surfaces. Apply 483 kPa (70 psi) air pressure to the element to check for leaks. If the element leaks, replace the element. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Procedures > Page 3267 Oil Cooler: Removal and Replacement Removal REMOVAL - OIL COOLER 1. Disconnect Negative battery cables. 2. Drain Coolant. 3. Disconnect Ambient Air and MAF Sensors on Air Filter housing. 4. Loosen hose clamp at Turbocharger Inlet. 5. Move clamp on Engine Breather hose at Inlet elbow at turbocharger and remove hose. 6. Remove Air Filter housing cover and inlet hose and set aside. 7. Remove upper generator bolt, loosen lower generator bolt, and rotate generator away from cylinder head. 8. Loosen the three clamps and hoses from the Coolant outlet tube. 9. Loosen and remove the bracket attachment nut from Coolant tube (10 mm). 10. Remove Coolant outlet tube. 11. Loosen turbocharger oil supply hose from oil cooler housing. 12. Remove oil filter. 13. Loosen and remove the 14 oil cooler attachment capscrews (10 mm). 14. Remove oil cooler housing and oil cooler from engine block. Installation INSTALLATION 1. Clean block surface, oil cooler, and oil cooler housing of debris, dirt and remaining gasket material 2. Using new gaskets install oil cooler, oil cooler housing to cylinder block. NOTE: Depending on the revision of oil cooler, mounting gaskets will differ. Make sure the gaskets line up with the oil cooler element and housing correctly. Failure to use correct gaskets will result in severe engine damage. 3. Tighten mounting capscrews in a criss-cross pattern. Torque to 24 Nm (18 ft-lb) 4. Install Coolant outlet tube into place and secure tube bracket to cooler mounting stud. Tighten nut to 24 Nm (18 ft-lb) 5. Connect tube to hoses and secure with hose clamps 6. Swing generator into place and torque through bolts to specs. 7. Install Air Inlet hose to turbocharger and place Air Filter housing lid into place 8. Tighten hose clamp at Turbocharger to specs. 9. Install Crank Case Breather hose to Inlet elbow and place hose clamp in place. 10. Connect Ambient Air and MAP sensors. 11. Fill Engine with coolant. 12. Connect battery cables. 13. Start engine and check for leaks. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Page 3268 Oil Cooler: Tools and Equipment 1/2" Oil Cooler Line Rem. AST tool# 8016 Used for removing both of the oil cooler lines from the fittings on automatic transmission and oil coolers. - Used for R and R of Oil and Transmission Cooler Lines - Green-Anodized Aluminum Construction - See Application Chart - Included in the 8100, 8107 and #8110 Line Disconnect Sets. Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Tool is also available in the following kits: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Page 3269 8107 - 7-Piece Line Disconnect Set 8110 - 10-Pc. Line Disconnect Set Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Removal Oil Filter: Service and Repair Removal REMOVAL 1. Clean the area around the oil filter head. Remove the filter from below using a cap-style filter wrench. 2. Clean the gasket surface of the filter head. The filter canister O-Ring seal can stick on the filter head. Make sure it is removed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Removal > Page 3274 Oil Filter: Service and Repair Installation INSTALLATION 1. Fill the oil filter element with clean oil before installation. Use the same type oil that will be used in the engine. 2. Apply a light film of lubricating oil to the sealing surface before installing the filter. CAUTION: Mechanical over-tightening may distort the threads or damage the filter element seal. 3. Install the filter until it contacts the sealing surface of the oil filter adapter. Tighten filter an additional 1/2 turn. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Engine > Component Information > Service and Repair > Procedures Oil Line: Procedures CLEANING AND INSPECTION Clean the sealing surfaces. Apply 483 kPa (70 psi) air pressure to the element to check for leaks. If the element leaks, replace the element. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Engine > Component Information > Service and Repair > Procedures > Page 3279 Oil Line: Removal and Replacement Removal REMOVAL - OIL COOLER 1. Disconnect Negative battery cables. 2. Drain Coolant. 3. Disconnect Ambient Air and MAF Sensors on Air Filter housing. 4. Loosen hose clamp at Turbocharger Inlet. 5. Move clamp on Engine Breather hose at Inlet elbow at turbocharger and remove hose. 6. Remove Air Filter housing cover and inlet hose and set aside. 7. Remove upper generator bolt, loosen lower generator bolt, and rotate generator away from cylinder head. 8. Loosen the three clamps and hoses from the Coolant outlet tube. 9. Loosen and remove the bracket attachment nut from Coolant tube (10 mm). 10. Remove Coolant outlet tube. 11. Loosen turbocharger oil supply hose from oil cooler housing. 12. Remove oil filter. 13. Loosen and remove the 14 oil cooler attachment capscrews (10 mm). 14. Remove oil cooler housing and oil cooler from engine block. Installation INSTALLATION 1. Clean block surface, oil cooler, and oil cooler housing of debris, dirt and remaining gasket material 2. Using new gaskets install oil cooler, oil cooler housing to cylinder block. NOTE: Depending on the revision of oil cooler, mounting gaskets will differ. Make sure the gaskets line up with the oil cooler element and housing correctly. Failure to use correct gaskets will result in severe engine damage. 3. Tighten mounting capscrews in a criss-cross pattern. Torque to 24 Nm (18 ft-lb) 4. Install Coolant outlet tube into place and secure tube bracket to cooler mounting stud. Tighten nut to 24 Nm (18 ft-lb) 5. Connect tube to hoses and secure with hose clamps 6. Swing generator into place and torque through bolts to specs. 7. Install Air Inlet hose to turbocharger and place Air Filter housing lid into place 8. Tighten hose clamp at Turbocharger to specs. 9. Install Crank Case Breather hose to Inlet elbow and place hose clamp in place. 10. Connect Ambient Air and MAP sensors. 11. Fill Engine with coolant. 12. Connect battery cables. 13. Start engine and check for leaks. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil pan-Bolts ........................................................................................................................................ .................................................... 28 Nm (21 ft. lbs.) NOTE: Start in the center and work outward. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Procedures Oil Pan: Procedures Cleaning CLEANING Remove all gasket material from the oil pan and cylinder block sealing surfaces. Extra effort may be required around T-joint areas. Clean oil pan and flush suction tube with a suitable solvent. Inspection INSPECTION Inspect the oil pan, suction tube, and tube braces for cracks and damage. Replace any defective component. Inspect the oil drain plug and drain hole threads. Inspect the oil pan sealing surface for straightness. Repair any minor imperfections with a ball-peen hammer. Do not attempt to repair an oil pan by welding. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Procedures > Page 3285 Oil Pan: Removal and Replacement Removal REMOVAL 4x4 1. Open the hood. 2. Disconnect the battery negative cables. 3. Remove the intake air assembly. 4. Remove the radiator shroud retaining bolts. 5. Install engine support fixture # 8534B. 6. Raise and support the vehicle. WARNING: HOT OIL CAN CAUSE PERSONAL INJURY. 7. Drain the engine oil. 8. Loosen the front engine mount bolts. 9. Lower the vehicle. 10. Use the engine support fixture #8534B to raise engine out of the front mounts. 11. Remove the engine oil dipstick. 12. Raise and support the vehicle. 13. Remove oil pan bolts, break the pan to block seal, and lower pan slightly and remove oil suction tube fasteners. 14. Remove oil pan and suction tube. 15. Remove the 2 bolts from the front of the engine block stiffener. 16. Remove the oil pan. 4x2 1. Open the hood. 2. Remove the negative battery cables. 3. Raise and support the vehicle. 4. Remove the transmission oil cooler lines. 5. Remove the propeller shaft. 6. Remove the starter bolts. 7. Support the starter. 8. Remove the torque converter bolts. 9. Remove the exhaust hanger bolts. 10. Remove the gear shift cable. 11. Remove the wiring harness. 12. Remove the transmission mount. 13. Remove the crossover bolts. 14. Position the transmission jack. 15. Remove the bell housing bolts. 16. Remove the transmission. 17. Remove the flywheel housing bolts (8). 18. Remove the flex plate bolts (8). 19. Remove the engine oil dip stick. 20. Drain the oil. 21. Remove the steering rack bolts. 22. Remove the oil pan bolts. 23. Remove the oil pickup bolts. 24. Remove the oil pan. Installation INSTALLATION 4x4 1. Clean the sealing surfaces of the cylinder block and oil pan with a suitable cleaner. 2. Clean the oil pan. 3. Clean the oil pan T-joints. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Procedures > Page 3286 4. Fill the T-joint between the pan rail/gear housing and pan rail/rear seal retainer with sealant. Use Mopar® Silicone Rubber Adhesive Sealant or equivalent. 5. Position the new oil pan gasket. 6. Place suction tube in oil pan and guide them into place. Using a new tube-to-block gasket, install and tighten the suction tube bolts by hand. Starting with the oil pump inlet bolts, tighten the bolts to 24 Nm (18 ft. lbs.) torque. Tighten the remaining tube brace bolts to 43 Nm (32 ft. lbs.) torque. 7. Starting in the center and working outward, tighten the oil pan bolts to 28 Nm (21 ft. lbs.) torque. 8. Install the engine oil dipstick. 9. Install the engine block stiffener. 10. Install the flywheel to crankshaft adapter. Torque to 137 Nm (101 ft. lbs.). 11. Lower vehicle. 12. Lower the engine into the motor mounts and tighten the through bolts to 88 Nm (64 ft. lbs.). 13. Install battery negative cables. 14. Fill the crankcase with new engine oil. 15. Start engine and check for leaks. Stop engine, check oil level, and adjust, if necessary. 16. Remove the engine support fixture #8534B. 17. Install the fan and fan shroud. NOTE: Make sure that the fan shroud seal is properly seated in the radiator fan shroud and that it is not out of position causing excessive contact with the radiator coolant tubes. 18. Fill the engine oil. 19. Connect the battery negative cables. 20. Close the hood. 4x2 1. Clean the sealing surfaces of the cylinder block and oil pan with a suitable cleaner. 2. Clean the oil pan. 3. Clean the oil pan T-joints. 4. Fill the T-joint between the pan rail/gear housing and pan rail/rear seal retainer with sealant. Use Mopar® Silicone Rubber Adhesive Sealant or equivalent. 5. Position the new oil pan gasket. 6. Place suction tube in oil pan and guide them into place. Using a new tube-to-block gasket, install and tighten the suction tube bolts by hand. Starting with the oil pump inlet bolts, tighten the bolts to 24 Nm (18 ft. lbs.) torque. Tighten the remaining tube brace bolts to 43 Nm (32 ft. lbs.) torque. 7. Starting in the center and working outward, tighten the oil pan bolts to 28 Nm (21 ft. lbs.) torque. 8. Install the steering rack bolts. 9. Install the flex plate. 10. Install the flywheel to crankshaft adapter. Torque to 137 Nm (101 ft. lbs.). 11. Install transmission and transfer case (if equipped). 12. Install the flywheel housing assembly with the starter motor attached and tighten bolts to 77 Nm (57 ft. lbs.) torque. NOTE: A new clamping ring must be used on early or late builds, automatic or manual. Do not reuse clamping ring. 13. Install the EGR cooler. 14. Install the fan and fan shroud. NOTE: Make sure that the fan shroud seal is properly seated in the radiator fan shroud and that it is not out of position causing excessive contact with the radiator coolant tubes. 15. Remove the transmission jack. 16. Install the crossmember bolts. 17. Install the transmission mount. 18. Install the wiring harness. 19. Install the gear shift cable. 20. Install the exhaust hanger bolts. 21. Install the torque converter bolts. 22. Install the starter. 23. Install the starter bolts. 24. Install the transmission oil cooler lines. 25. Connect the negative battery cables. 26. Close the hood. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Description and Operation > Description Oil Pressure Gauge: Description and Operation Description DESCRIPTION An oil pressure gauge is standard equipment on all instrument clusters. This gauge is located in the upper right quadrant of the instrument cluster, above the coolant temperature gauge. This gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from L (or Low) to H (or High) for gasoline engines. On vehicles with a diesel engine the scale reads from 0 kPa to 760 kPa in markets where a metric instrument cluster is specified, or from 0 psi to 110 psi in all other markets. An International Control and Display Symbol icon for Engine Oil is located on the cluster overlay, directly below the left end of the gauge scale. The oil pressure gauge graphics are black against a white field except for a single red graduation at the low end of the gauge scale making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster general illumination lighting with the exterior lamps turned ON, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The oil pressure gauge is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Description and Operation > Description > Page 3291 Oil Pressure Gauge: Description and Operation Operation OPERATION The oil pressure gauge gives an indication to the vehicle operator of the engine oil pressure. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Controller Area Network (CAN) data bus. The oil pressure gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Oil Pressure Message - The instrument cluster circuitry restricts the oil pressure gauge needle operation in order to provide readings that are consistent with customer expectations. Each time the cluster receives an electronic engine oil pressure message from the PCM or ECM indicating the pressure is above about 41 kPa (6 psi) the cluster holds the gauge needle at a point near the middle increment within the normal range on the gauge scale. - Engine Oil Pressure Low Message - Each time the cluster receives three consecutive electronic engine oil pressure messages from the PCM or ECM indicating the pressure is below about 41 kPa (6 psi), the gauge needle is moved to the red graduation at the far left end of the gauge scale, the check gauges indicator is illuminated, and a single chime tone is generated. The gauge needle remains at the left end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the pressure is above about 41 kPa (6 psi), or until the ignition switch is turned to the OFF position, whichever occurs first. The cluster will only turn ON the check gauges indicator in response to a low pressure message if the engine speed is greater than zero. - Communication Error - If the cluster fails to receive an engine oil pressure message, it will hold the gauge needle at the last indication for about 10 seconds, or until the ignition switch is turned to the OFF position, whichever occurs first. After 10 seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the oil pressure gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM (gasoline engines) or ECM (diesel engines) continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM or ECM then sends the proper messages to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the oil pressure gauge or the instrument cluster circuitry that controls the gauge refer to Instrument Cluster/Carrier Testing. If the instrument cluster turns ON the check gauges indicator due to a low oil pressure gauge reading, it may indicate that the engine or the engine oiling system requires service. For proper diagnosis of the engine oil pressure sensor, the PCM, the ECM, the EMIC, the CAN data bus or the electronic communication related to oil pressure gauge operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Component ID: 473 Component : SWITCH-OIL PRESSURE Connector: Name : SWITCH-OIL PRESSURE Color : BLACK # of pins : 2 Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 18VT/GY Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 16VT/GY 2-Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3295 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3296 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3297 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3298 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3299 Oil Pressure Sender: Diagrams Component ID: 473 Component : SWITCH-OIL PRESSURE Connector: Name : SWITCH-OIL PRESSURE Color : BLACK # of pins : 2 Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 18VT/GY Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 16VT/GY 2-Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3300 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3301 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3302 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3303 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Service and Repair > Removal Oil Pressure Sender: Service and Repair Removal REMOVAL NOTE: When installing a new oil pressure switch, the kit will include a special 90° fitting that must be installed. Clock the fitting and switch assembly between the 1:00 o'clock and 2:00 o'clock position. Torque the fitting bolt to 18 Nm (13 ft. lbs) 1. Disconnect the battery negative cables. 2. Disconnect the oil pressure switch connector. 3. Using a suitable socket, remove the oil pressure switch from the block (counter-clockwise). 4. Remove the banjo screw from the oil pressure switch mounting block. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Service and Repair > Removal > Page 3306 Oil Pressure Sender: Service and Repair Installation INSTALLATION 1. Install banjo screw through the oil pressure switch mounting block. The switch mounting block port (oil switch port) should point to the 2 o'clock position. Torque the banjo screw to 24 Nm or 18 ft lbs. 2. If the switch is not being replaced, replace and lubricate the o-ring. 3. Install the oil pressure switch and tighten to 18 Nm (159 in. lbs.) torque. 4. Connect oil pressure switch connector. 5. Connect the battery negative cables. 6. Start engine and check for oil leaks at the switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3311 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3312 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3313 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3314 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3315 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3316 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3317 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3318 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3319 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3320 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3321 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3322 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3323 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3324 Oil Pressure Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3325 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3326 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3327 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3328 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure Oil Pressure Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 3333 Engine Oil Pressure: Testing and Inspection DIAGNOSIS AND TESTING-ENGINE OIL PRESSURE 1. Remove the 1/8 npt plug from the top of the oil filter housing. 2. Install Oil Pressure Line and Gauge Tool C-3292 with a suitable adapter. 3. Start engine and warm to operating temperature. 4. Record engine oil pressure and compare with engine oil pressure chart. CAUTION: If engine oil pressure is zero at idle, DO NOT RUN THE ENGINE. If minimum engine oil pressure is below these ranges, Refer to ENGINE - TESTING. 5. Remove oil pressure gauge and install the 1/8 npt plug. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications Intake manifold capscrews to .............................................................................................................. ..................................................... 24 Nm (18 ft. lbs.) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures Intake Manifold: Procedures Cleaning CLEANING Clean manifold in solvent and blow dry with compressed air. Clean cylinder block gasket surfaces using a suitable solvent. The plenum pan rail must be clean and dry (free of all foreign material). Inspection INSPECTION Inspect manifold for cracks. Inspect mating surfaces of manifold for flatness with a straightedge. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 3339 Intake Manifold: Removal and Replacement Removal REMOVAL 1. Disconnect the batteries. 2. Disconnect the EGR air Transfer tube temperature sensor. 3. Disconnect the EGR Valve Actuator Connector 4. Disconnect the Engine Oil level tube at the Air Inlet bracket 5. Loosen the CAC Outlet tube clamps at the CAC Outlet and Air Inlet and remove the tube. 6. Loosen and remove both v-band clamps at each end of the Air Transfer tube 7. Remove the P-clip mounting capscrew 8. Remove the Air Transfer tube 9. Loosen and remove six (6) Air Inlet mounting capscrews. 10. Remove the air inlet. 11. Remove the injector fuel lines. 12. Disconnect the Fuel Rail Pressure sensor at the rear of the fuel rail manifold. 13. Remove the High Pressure fuel line from the dump/overflow valve. 14. Remove the fuel rail. 15. Remove the grid heater wiring connector. 16. Disconnect the TMAP sensor. 17. Remove the intake manifold capscrews. 18. Remove the intake manifold. Installation INSTALLATION 1. Clean the Intake Manifold and Cylinder Head Gasket area. 2. Install a new intake manifold gasket. 3. Position the intake manifold and Install the intake manifold capscrews finger tight. 4. Position the fuel rail and install the fuel rail manifold capscrews finger tight. 5. Torque the intake manifold capscrews to 24 N.m (18 ft. lbs.). 6. Connect the fuel rail pressure sensor. 7. Connect the intake manifold grid heater. Torque the capscrew to 10 N.m (89 in. lbs.). 8. Install the fuel lines. 9. Torque the fuel rail mounting capscrews to 24 N.m (18 ft. lbs.). 10. Clean the Air Inlet gasket area. 11. Clean the Intake Manifold to air inlet area. 12. Install the new Air Intake connection gasket. 13. Install the air intake connection to the intake manifold 14. torque the intake manifold to 24 N.m (18 lbs. ft.). 15. Install the Oil Level Gauge tube and torque to 24 N.m (18 lbs. ft.). 16. Clean the gasket area of the Air Transfer Tube (both ends). 17. Clean the EGR cooler and EGR control valve gasket area. 18. Using new gaskets, install the Air Transfer Tube. 19. Install the V-band clamps. 20. Install the P-clip to the bracket. Torque the mounting capscrew to 24 N.m (18 lbs. ft.). 21. Torque the V-band clamps to 10 N.m (89 lbs. in.). 22. Connect the EGR Valve Actuator connector. 23. Connect the EGR Gas Temperature connector. 24. Connect the batteries. 25. Start the engine and check for leaks. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Description and Operation > Description Oil Pressure Gauge: Description and Operation Description DESCRIPTION An oil pressure gauge is standard equipment on all instrument clusters. This gauge is located in the upper right quadrant of the instrument cluster, above the coolant temperature gauge. This gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from L (or Low) to H (or High) for gasoline engines. On vehicles with a diesel engine the scale reads from 0 kPa to 760 kPa in markets where a metric instrument cluster is specified, or from 0 psi to 110 psi in all other markets. An International Control and Display Symbol icon for Engine Oil is located on the cluster overlay, directly below the left end of the gauge scale. The oil pressure gauge graphics are black against a white field except for a single red graduation at the low end of the gauge scale making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster general illumination lighting with the exterior lamps turned ON, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The oil pressure gauge is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Description and Operation > Description > Page 3345 Oil Pressure Gauge: Description and Operation Operation OPERATION The oil pressure gauge gives an indication to the vehicle operator of the engine oil pressure. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Controller Area Network (CAN) data bus. The oil pressure gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Oil Pressure Message - The instrument cluster circuitry restricts the oil pressure gauge needle operation in order to provide readings that are consistent with customer expectations. Each time the cluster receives an electronic engine oil pressure message from the PCM or ECM indicating the pressure is above about 41 kPa (6 psi) the cluster holds the gauge needle at a point near the middle increment within the normal range on the gauge scale. - Engine Oil Pressure Low Message - Each time the cluster receives three consecutive electronic engine oil pressure messages from the PCM or ECM indicating the pressure is below about 41 kPa (6 psi), the gauge needle is moved to the red graduation at the far left end of the gauge scale, the check gauges indicator is illuminated, and a single chime tone is generated. The gauge needle remains at the left end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the pressure is above about 41 kPa (6 psi), or until the ignition switch is turned to the OFF position, whichever occurs first. The cluster will only turn ON the check gauges indicator in response to a low pressure message if the engine speed is greater than zero. - Communication Error - If the cluster fails to receive an engine oil pressure message, it will hold the gauge needle at the last indication for about 10 seconds, or until the ignition switch is turned to the OFF position, whichever occurs first. After 10 seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the oil pressure gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM (gasoline engines) or ECM (diesel engines) continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM or ECM then sends the proper messages to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the oil pressure gauge or the instrument cluster circuitry that controls the gauge refer to Instrument Cluster/Carrier Testing. If the instrument cluster turns ON the check gauges indicator due to a low oil pressure gauge reading, it may indicate that the engine or the engine oiling system requires service. For proper diagnosis of the engine oil pressure sensor, the PCM, the ECM, the EMIC, the CAN data bus or the electronic communication related to oil pressure gauge operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Removal Crankshaft Main Bearing Seal: Service and Repair Removal REMOVAL 1. Disconnect the battery negative cables. 2. Remove the transmission and transfer case (if equipped). 3. Remove the clutch cover and disc (if manual transmission equipped). 4. Remove the flywheel or converter drive plate. 5. Remove the flywheel adapter plate. 6. Drill holes 180° apart into the seal. Be careful not to contact the drill against the crankshaft. 7. Install #10 sheet metal screws (1) in the drilled holes and remove the rear seal with a slide hammer (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Removal > Page 3351 Crankshaft Main Bearing Seal: Service and Repair Installation INSTALLATION CAUTION: The seal lip and the sealing surface on the crankshaft must be free from all oil residue to prevent seal leaks. The crankshaft and seal surfaces must be completely dry when the seal is installed. Use a soap and water solution on outside diameter of seal to ease assembly. 1. Clean the crankshaft journal with a suitable solvent and dry with a clean shop towel or compressed air. Wipe the inside bore of the crankshaft seal retainer with a clean shop towel. 2. Inspect the crankshaft journal for gouges, nicks, or other imperfections. If the seal groove in the crankshaft is excessively deep, install the new seal 1/8" deeper into the retainer bore, or obtain a crankshaft wear sleeve that is available in the aftermarket. 3. Install the seal pilot and new seal, provided in the replacement kit, onto the crankshaft. 4. Remove the seal pilot. 5. Install the installation tool over crankshaft. 6. Using a ball peen hammer, strike the tool (2) at the 12, 3, 6, and 9 o'clock positions until the alignment tool bottoms out on the retainer. NOTE: Always install a new clamping ring, never reuse the old clamping ring. 7. Install the flywheel or converter drive plate, and clamping ring. Tighten the bolts to 137 Nm (101 ft. lbs.) torque. 8. Install the clutch cover and disc (if equipped). 9. Install the transmission and transfer case (if equipped). 10. Lower vehicle. 11. Connect battery negative cables. 12. Check engine oil level and adjust, if necessary. 13. Start engine and check for oil leaks. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Removal Front Crankshaft Seal: Service and Repair Removal REMOVAL 1. Disconnect both battery negative cables. 2. Raise vehicle on hoist. 3. Partially drain engine coolant into container suitable for re-use. 4. Lower vehicle. 5. Remove radiator upper hose. 6. Disconnect coolant recovery bottle hose from radiator filler neck. 7. Disconnect windshield washer pump supply hose and electrical connections and lift washer bottle off of fan shroud. 8. Remove viscous fan/drive assembly. 9. Remove cooling fan shroud and fan assembly from the vehicle. 10. Remove the accessory drive belt. 11. Remove the cooling fan support/hub from the front of the engine. 12. Raise the vehicle on hoist. 13. Remove the crankshaft damper. 14. Remove power steering pump. 15. Remove accessory drive belt tensioner. 16. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar the gasket surfaces. Remove crank seal dust shield with cover. 17. Support the cover on a flat work surface with wooden blocks, and using a suitable punch (1) and hammer, drive the old seal out of the cover from the back side of the cover to the front side. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Removal > Page 3356 Front Crankshaft Seal: Service and Repair Installation INSTALLATION CAUTION: The seal lip and the sealing surface on the crankshaft must be free of all oil residue, to prevent leaks. The crankshaft and seal surface must be completely dry when the seal is installed. 1. Clean cover and housing gasket mating surfaces. Use a suitable scraper and be careful not to damage the gear housing surface. Remove any old sealer from the oil seal bore. Thoroughly clean the front seal area of the crankshaft. Do not sand this surface. The seal lip and the sealing surface on the crankshaft must be free from all oil residue to prevent seal leaks. 2. Inspect the gear housing and cover for cracks and replace if necessary. Carefully straighten any bends or imperfections in the gear cover with a ball-peen hammer on a flat surface. Inspect the crankshaft front journal for any grooves or nicks that would affect the integrity of the new seal. 3. Apply a bead of Mopar(R) Stud & Bearing Mount to the outside diameter of the seal. Do not lubricate the inside diameter of the new seal. 4. With the cover supported by wood blocks, install the seal into the rear of the cover using crankshaft seal installer Special Tool 8281 and driver handle C-4171. Strike the driver handle until the installation tool bottoms out on the inside of the cover. CAUTION: Do not distort or damage seal. 5. Install the plastic seal pilot (provided with seal kit) into the crankshaft seal. 6. Apply a bead of Mopar(R) Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover sealing surface. 7. Install the cover to the gear housing, aligning the seal pilot with the nose of the crankshaft. NOTE: Failure to follow the cover installation procedure can result in misalignment of the crankshaft seal to the crankshaft, causing an oil leak. 8. Install the cover bolts and hand snug 2 capscrews at the 3 o'clock and 9 o'clock position, to keep the cover from moving when the first capscrew is torqued. Torque to 24 Nm (18 ft. lbs.) torque. Remove pilot tool. 9. Install dust shield over nose of crankshaft. 10. Install the crankshaft damper. Torque the bolts to 40 Nm (30 ft. lbs.). Then rotate an additional 60°. Use the engine barring tool to keep the engine from rotating during tightening operation. 11. Install the fan support/hub assembly and torque bolts to 32 Nm (24 ft. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Removal > Page 3357 12. Install power steering pump. 13. Install accessory drive belt tensioner. Torque bolt to 43 Nm (32 ft.lbs.). 14. Install cooling fan. 15. Install the accessory drive belt. 16. Refill cooling system. 17. Connect battery negative cables. 18. Start engine and check for oil leaks. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Oil Pan Gasket, Engine > Component Information > Service and Repair > Removal Oil Pan Gasket: Service and Repair Removal REMOVAL 1. Disconnect the battery. 2. Remove the intake air assembly. 3. Remove the inner radiator shroud retaining bolts. 4. Remove the inner radiator shroud. 5. Raise and support the vehicle. 6. Remove the front suspension rear tie bar. 7. Remove the left engine mount through bolt. 8. Remove the right engine mount through bolt. 9. Remove the rack and pinion retaining bolts. 10. Drain the engine oil. 11. Lower the vehicle. 12. Install the engine lift fixture. 13. Use the engine lift fixture to raise the engine. 14. Raise the vehicle on the hoist. 15. Remove the oil pan retaining bolts. 16. Lower the oil pan enough to allow the removal of the oil pan gasket. 17. Remove the oil pan gasket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Oil Pan Gasket, Engine > Component Information > Service and Repair > Removal > Page 3362 Oil Pan Gasket: Service and Repair Installation INSTALLATION 1. Clean the oil pan gasket surfaces to be sure the surfaces are free of debris and oil. 2. Install a new oil pan gasket. 3. Install the oil pan bolts in a cross pattern. 4. Install the rack and pinion bolts. 5. Lower the vehicle. 6. Lower the engine into the mounts. 7. Remove the engine lift fixture. 8. Fill the engine with oil. 9. Raise and support the vehicle. 10. Install the left engine mount through bolt. 11. Install the right engine mount through bolt. 12. Install the front suspension rear tie bolts. 13. Lower the vehicle. 14. Install the radiator shroud. 15. Install the radiator shroud bolts. 16. Install the intake air assembly. 17. Connect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Component ID: 473 Component : SWITCH-OIL PRESSURE Connector: Name : SWITCH-OIL PRESSURE Color : BLACK # of pins : 2 Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 18VT/GY Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 16VT/GY 2-Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3367 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3368 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3369 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3370 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3371 Oil Pressure Sender: Diagrams Component ID: 473 Component : SWITCH-OIL PRESSURE Connector: Name : SWITCH-OIL PRESSURE Color : BLACK # of pins : 2 Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 18VT/GY Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 16VT/GY 2-Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3372 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3373 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3374 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3375 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Removal Oil Pressure Sender: Service and Repair Removal REMOVAL NOTE: When installing a new oil pressure switch, the kit will include a special 90° fitting that must be installed. Clock the fitting and switch assembly between the 1:00 o'clock and 2:00 o'clock position. Torque the fitting bolt to 18 Nm (13 ft. lbs) 1. Disconnect the battery negative cables. 2. Disconnect the oil pressure switch connector. 3. Using a suitable socket, remove the oil pressure switch from the block (counter-clockwise). 4. Remove the banjo screw from the oil pressure switch mounting block. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Removal > Page 3378 Oil Pressure Sender: Service and Repair Installation INSTALLATION 1. Install banjo screw through the oil pressure switch mounting block. The switch mounting block port (oil switch port) should point to the 2 o'clock position. Torque the banjo screw to 24 Nm or 18 ft lbs. 2. If the switch is not being replaced, replace and lubricate the o-ring. 3. Install the oil pressure switch and tighten to 18 Nm (159 in. lbs.) torque. 4. Connect oil pressure switch connector. 5. Connect the battery negative cables. 6. Start engine and check for oil leaks at the switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3383 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3384 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3385 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3386 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3387 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3388 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3389 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3390 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3391 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3392 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3393 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3394 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3395 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3396 Oil Pressure Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3397 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3398 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3399 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3400 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Component Alignment Marks > Component Information > Locations Timing Component Alignment Marks: Locations Install the camshaft. Align the crankshaft and camshaft gear marks as shown. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Tighten the bolts at the 3 and 9 o'clock position finger tight, then in a clockwise direction starting at the 3 o'clock position, torque to 24 Nm (18 ft. lbs.) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Case - Front Timing Cover: Service and Repair Case - Front Removal REMOVAL 1. Disconnect the battery negative cables. 2. Raise vehicle on hoist. 3. Partially drain engine coolant into container suitable for re-use. 4. Lower vehicle. 5. Remove radiator upper hose. 6. Disconnect coolant recovery bottle hose from radiator filler neck. 7. Remove viscous fan/drive/shroud assembly. 8. Remove the accessory drive belt. 9. Remove the cooling fan support/hub from the front of the engine. 10. Raise the vehicle on hoist. 11. Remove the crankshaft damper. 12. Remove the lower fan shroud bracket. 13. Remove the upper fan shroud bracket that is mounted to the gear housing. 14. Lower the vehicle. 15. Remove the power steering pump. 16. Remove the accessory drive belt tensioner. 17. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar the gasket surfaces. 18. Remove the fuel injection pump. 19. Disconnect the camshaft position sensor connector. 20. Disconnect and remove engine speed sensor. 21. Remove the camshaft. 22. Remove the six front oil pan fasteners. 23. Remove the gear housing fasteners. NOTE: Use care when removing the gear housing, to avoid damage to the oil pan gasket, as the gasket will be reused if it is not damaged. 24. Slide a feeler gauge between the gear housing and oil pan gasket, to break the gasket seal. 25. Remove the gear housing and gasket. 26. Clean the gasket material from the cylinder block and gear housing. Installation INSTALLATION 1. Inspect oil pan gasket. If torn, gasket must be replaced. 2. Install a new gear housing gasket onto cylinder block and trim any excess gasket material flush to oil pan rail. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Case - Front > Page 3410 3. Place a small amount of Mopar(R) engine RTV to the corners of the block and pan gasket T-joint to ensure a good seal. 4. Install the gear housing. Torque bolts to 24 Nm (18 ft. lbs.). 5. If a new housing is installed, the camshaft position sensor, and engine speed sensor must be transferred to the new housing. 6. Connect the camshaft position sensor connector. 7. Install and connect engine speed sensor. 8. Install the injection pump. 9. Install the camshaft. Align the crankshaft and camshaft gear marks as shown. 10. Install a new front crankshaft seal into the gear cover. 11. Apply a bead of Mopar(R) Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover. Be sure to surround all through holes. 12. Using the seal pilot to align the cover, install the cover to the housing and install the bolts. Tighten the bolts at the 3 and 9 o'clock position finger tight, then in a clockwise direction starting at the 3 o'clock position, torque to 24 Nm (18 Ft lbs). 13. Snug, but do not torque one bolt at the 3 o'clock and 9 o'clock positions. This center's the seal on the crankshaft. 14. Tighten the bolt to 24 Nm (18 ft. lbs.) torque in a circular pattern. 15. Remove the seal pilot. Install front seal dust shield. 16. Raise the vehicle. 17. Install the crankshaft damper. Torque bolts to 40 Nm (30 ft. lbs.), plus an additional 60°. 18. Install the lower fan shroud bracket. Torque bolts to 24 Nm (18 ft. lbs.) torque. 19. Install the upper fan shroud brackets. Hand tighten only. 20. Lower vehicle. 21. Install the fan support/hub assembly and tighten bolts to 32 Nm (24 ft. lbs.) torque. 22. Install the power steering pump. 23. Install the accessory drive belt tensioner. Torque bolt to 43 Nm (32 ft. lbs.) torque. 24. Install the accessory drive belt. 25. Install the upper cooling fan/drive/shroud assembly. 26. Torque the upper fan shroud brackets to 24 Nm (18 ft. lbs.) torque. 27. Connect the coolant recovery bottle hose to the radiator filler neck. 28. Install the radiator upper hose and clamps. 29. Add engine oil. 30. Add coolant. 31. Connect the battery cables. 32. Start engine and inspect for leaks. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Case - Front > Page 3411 Timing Cover: Service and Repair Cover - Timing Removal REMOVAL 1. Disconnect both battery negative cables. 2. Raise vehicle on hoist. 3. Partially drain engine coolant into container suitable for re-use. 4. Lower vehicle. 5. Remove radiator upper hose. 6. Remove viscous fan/drive/shroud assembly. 7. Remove the accessory drive belt. 8. Remove the cooling fan support/hub from the front of the engine. 9. Raise the vehicle on hoist. 10. Remove power steering pump. 11. Remove accessory drive belt tensioner. 12. Remove the crankshaft damper. 13. Lower the vehicle. 14. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar the gasket surfaces. Installation INSTALLATION 1. Install a new front crankshaft oil seal. 2. Obtain a seal pilot (1) installation tool from a crankshaft front seal service kit and install the pilot into the seal. 3. Apply a bead of Mopar(R) Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover. Be sure to surround all through holes. 4. Using the seal pilot to (1) align the cover , install the cover to the housing and install the bolts. Tighten the bolts at the 3 and 9 o'clock position finger tight, then in a clockwise direction starting at the 3 o'clock position, torque to 24 Nm (18 Ft. lbs). 5. Snug, but do not torque one bolt at the 3 o'clock and 9 o'clock positions. This centers the seal on the crankshaft. 6. Tighten the bolts to 24 Nm (18 ft. lbs.) in a circular pattern. 7. Remove the seal pilot. Install front seal dust shield. 8. Raise the vehicle. 9. Install the crankshaft damper. 10. Lower vehicle. 11. Install the fan support/hub assy, and tighten bolts to 32 Nm (24 ft. lbs.) torque. 12. Install power steering pump. 13. Install accessory drive belt tensioner. Torque bolt to 43 Nm (32 ft. lbs.) torque. 14. Install the accessory drive belt. 15. Install the cooling fan/drive/shroud assembly. 16. Install the radiator upper hose and clamps. 17. Add coolant. 18. Connect the battery cables. 19. Start engine and inspect for leaks. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL PRESSURES Fuel Pump/Gear Pump (low pressure) ................................................................................................................................ 551.5 - 1241 KPA (80 - 180 psi) Injection Pump ..................................................................................................................................... ............................ 200 - 1800 bar (2900 - 26107 psi) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test Fuel Pressure: Testing and Inspection Fuel Pump Return Flow Test *FUEL PUMP RETURN FLOW TEST 1. FUEL PUMP RETURN FLOW TEST Using the scan tool, idle the engine and measure the rail pressure and determine if the rail pressure is excessive (above 185,00 kpa/26,831 psi). If it is, troubleshoot for excessive rail pressure first. Remove the banjo bolt from the pressure-limiting valve on the fuel rail. Install fuel system test fitting 9013 into the pressure-limiting valve. Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose into a container Perform the tests listed below to determine if the pressure-limiting valve is leaking. a. Operate the engine at idle and watch for fuel flow into the fuel container. b. Operate the engine at idle and actuate the high pressure safety valve test with the scan tool. Watch for fuel flow into the fuel container. If fuel flows into the fuel container, replace the pressure-limiting valve. If fuel does not leak from the pressure-limiting valve, the test is complete. NOTE: Do not drive the vehicle with any portion of this test kit installed Operate the engine until the engine is at operating temperature. Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing Install fuel system test fitting 9012 in place of the banjo connector. Install a piece of fuel line onto the test fitting and put the open end into the graduated cylinder . Start the engine and let it idle for one minute. Measure the amount of fuel in the graduated cylinder. If the flow is less than 1000ml/minute at idle, the test has successfully passed. If the flow is greater than 1000ml/minute at idle, replace the fuel injection pump. Retest to confirm repair. View Repair Repair - Test Complete. - Perform POWERTRAIN VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 3418 Fuel Pressure: Testing and Inspection High Pressure Fuel Pump Performance Test *HIGH PRESSURE FUEL PUMP PERFORMANCE TEST If the engine will run do the following: 1. Monitor rail pressure with scan tool while the engine is at idle. 2. Compare the fuel pressure set point with the actual fuel pressure reading. 3. If actual fuel pressure reading fluctuates more than ± 500 psi from the set point, then replace the Fuel Control Actuator (FCA). NOTE: After the actuator is removed, check for debris or corrosion on the FCA. If debris or corrosion is found, replace the entire Fuel Injection Pump. 4. Turn off engine. 5. Disconnect the FCA harness 6. Disconnect high pressure fuel line from fuel rail and route the high pressure fuel line into a graduated cylinder. 7. Crank the engine until fuel exits this line. This will not be high pressure fuel. 8. Crank the engine for three (3) 10 second intervals (Note: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter). Fuel flow specification s based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL If the engine is a no start do the following: 1. Remove fuel pump to rail high pressure fuel line. 2. Inspect the fuel pump outlet port for rust, debris, or other signs of contamination. 3. Replace pump if any contamination is found. Check for source of water in fuel or debris in fuel to prevent future complaints. If no contamination is found continue to step 4. 4. Disconnect the Fuel Control Actuator (FCA). 5. Disconnect the high pressure fuel line from the fuel rail and route the high pressure fuel line to a graduated cylinder. 6. Crank the engine until fuel exits this line. This will not be high pressure fuel. 7. Crank the engine for three (3) 10 seconds intervals. NOTE: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter. Fuel flow specification's based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 3419 Fuel Pressure: Testing and Inspection In-Tank Fuel Lift Pump Flow/Diagnostic Test Procedure *IN-TANK FUEL LIFT PUMP FLOW/DIAGNOSTIC TEST PROCEDURE 1. Using the Scan tool, check for DTCs. Troubleshoot any active DTCs before performing this test. 2. Disconnect the wiring harness from the lift pump at the fuel tank module connector and inspect the pins for damage. Fix or replace any damaged component. 3. Connect a voltmeter between the fuel lift pump supply and return pins at the fuel tank module connector. 4. Turn the ignition to the on position. Use the Scan tool to actuate the fuel lift pump, record the voltage on the voltmeter. 5. If the voltage is greater than 11.5 volts, go to step 14. If the voltage is less than 11.5 volts, go to step 6 6. Using a voltmeter, measure the battery voltage to determine that the voltage is greater than 11.5 volts. If the voltage is greater than 11.5 volts, go to step 7. If the voltage is not greater than 11.5 volts, troubleshoot for low battery voltage. 7. Remove the fuel lift pump relay from the PDC. Use a voltmeter to measure the voltage at the fuel lift pump relay voltage supply pin in the PDC. If the voltage is greater than 11.5 volts, go to step 8. If the voltage is not greater than 11.5 volts, fix or replace the harness. 8. Remove the fuel lift pump relay from the PDC. Install a spare relay in place of the fuel lift pump relay. Using the Scan tool, actuate the fuel lift pump. Use a voltmeter to measure the voltage between the fuel lift pump supply and return pins at the fuel tank module connector while the fuel lift pump is actuated. If the voltage is greater than 11.5 volts, replace the fuel lift pump relay. If the voltage is not greater than 11.5 volts, go to step 9. 9. Disconnect the wiring harness from the fuel tank module. Remove the lift pump relay from the PDC. Using an Ohmmeter, measure the resistance of the fuel lift pump power supply wire between the PDC relay output pin and the fuel tank module connector. If the resistance is less than 10 ohms, go to step 10. If it is greater than 10 ohms, fix or replace the harness. 10. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using a voltmeter, measure the voltage between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the voltage is less than 1 volt, go to step 11. If the voltage is greater than 1 volt, fix or replace the harness. 11. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using an ohmmeter, measure the resistance between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the resistance is less than 10 ohms, fix or replace the harness. If the resistance is greater than 10 ohms, go to step 12. 12. Disconnect the wiring harness from the fuel tank module. Using an Ohmmeter, measure the resistance of the fuel lift pump ground wire between the fuel tank module connector and battery negative. If the resistance is less than 10 ohms, go to step 13. If the resistance is greater than 10 ohms, fix or replace the harness. 13. Disconnect the wiring harness from the fuel tank module. Using a voltmeter, measure the voltage between the fuel lift pump ground wire and battery negative. If the voltage is less than 1 volt, go to step 14. If the voltage is greater than 1 volt, fix or replace the harness. 14. Reconnect the lift pump connector. FLOW TEST. 1. Remove the fuel pump supply banjo fitting from the fuel injection pump. 2. Install fuel system test fitting 9863 onto the end of the quick connect line going to the fuel injection pump. 3. Connect one end of a section of fuel hose to the test fitting. 4. Put the other end of the fuel hose into an empty fuel container. 5. Use the scan tool to actuate the fuel lift pump. 6. While the lift pump is running, move the fuel hose from the fuel canister into a 1000ml graduated cylinder for 10 seconds. 7. Read and record the amount of fuel in the graduated cylinder after 10 seconds. 8. If you have more than 570ml in the graduated cylinder after 10 seconds, the test has successfully passed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 3420 9. If you have less than 570ml of fuel in the graduated cylinder, inspect the fuel supply line from the fuel tank to the fuel filter housing and the fuel supply line between the fuel filter housing and the high pressure fuel pump for signs of damage, replace as necessary. If no damage is found, replace the fuel filter and retest. 10.Verify the Screened Banjo Bolt at the outlet of the fuel filter is free of debris. If debris is found, rinse screen with water, blow dry and reinstall. Retest vehicle. If flow meets specification then trace back the source of debris, if flow is still below spec repair damaged component. 11. If reading is still less than 570ml in 10 seconds, remove the fuel tank and fuel tank module. Inspect for damage and/or debris in and around the fuel tank module. If module is damaged, replace and retest. 12. If the module is not damaged, replace the fuel lift pump and retest to confirm fix. Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal Air Filter Element: Service and Repair Removal REMOVAL Testing Air Cleaner Element using Filter Minder(TM) Do not attempt to unnecessarily remove top of air cleaner housing for air cleaner element inspection on diesel engines. The air cleaner (filter) housing (5) is equipped with an air Filter Minder(TM) gauge (3). This air flow restriction gauge will determine when air cleaner element is restricted and should be replaced. The Filter Minder(TM) (5) consists of a diaphragm and calibrated spring sealed inside of a plastic housing. A yellow colored disc (2) attached to diaphragm moves along a graduated scale on side of Filter Minder. After the engine has been shut off, a ratcheting device located within Filter Minder will hold yellow disc at highest restriction that air cleaner element has experienced. A drop in air pressure due to an air cleaner element restriction moves diaphragm and yellow disc will indicate size of air drop. CAUTION: Certain engine degreasers or cleaners may discolor or damage plastic housing of Filter Minder. Cover and tape Filter Minder if any engine degreasers or cleaners are to be used. To test, turn engine off. If yellow disc (2) has reached red colored zone (3) on graduated scale, air cleaner element should be replaced. Refer to Removal / Installation. Resetting Filter Minder: After air cleaner (filter) element has been replaced, press rubber button on top of Filter Minder. This will allow yellow Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 3429 colored disc to reset. After button has been pressed, yellow disc should spring back to UP position. If Filter Minder gauge has reached red colored zone, and after an examination of air cleaner (filter) element, element appears to be clean, high reading may be due to a temporary condition such as snow build-up at air intake. Temporary high restrictions may also occur if air cleaner (filter) element has gotten wet such as during a heavy rain or snow. If this occurs, allow element to dry out during normal engine operation. Reset rubber button on top of Filter Minder and retest after element has dried. Filter Removal 1. The housing cover is equipped with spring clips and is hinged with plastic tabs. Unlatch clips from top of air cleaner housing and tilt housing cover up for cover removal. 2. Remove air cleaner element from air cleaner housing (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 3430 Air Filter Element: Service and Repair Installation INSTALLATION 1. Before installing new air cleaner element (filter), clean inside of air cleaner housing. 2. Position air cleaner cover to tabs on front of air cleaner housing. Latch spring clips to seal cover to housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit Fuel Filter: Technical Service Bulletins Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit NUMBER: 14-004-11 GROUP: Fuel System DATE: April 01, 2011 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-002-10, DATED FEBRUARY 11, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE NEW PARTS. SUBJECT: Heavy Duty Filtration MOPAR Retrofit or Add On Parts Available MODELS: 2003 - 2009 (D1/DH/DR) Ram Truck (2500/3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH/DR vehicles equipped with a 5.9L Cummins engine built from 2003 model year (sales codes ETH, ETC) and DC/DH/D1/vehicles equipped with a 6.7L Cummins engine built from 2007 model year (sales code ETJ). DISCUSSION: Several fuel system add-on or retrofit parts are available to enhance the filtering capability for customers exposing their vehicles to extremely dirty conditions. Description of parts available for Cummins diesel equipped vehicles are listed below: ^ **Severe duty, frame mounted fuel filter** (application for 2004.5 - 2009 Pickup & 2007 - 2010 Cab Chassis DC). ^ 6.7L up-graded (5 & 10 micron filter-in-filter) fuel filter to retrofit earlier models (shell and element). ^ 6.7L Element only, fuel filter. ^ 5.9L & 6.7L Add-on or up-graded fuel tank vent hose kit with vent cap. ^ Filter for fuel tank vent hose, (replaces vent cap). ^ 5.9L up-graded air filter. This filter is similar in design to the current 6.7L air filter. NOTE: Do not sell p/n 05183410AA fuel filter for (bottom load style) 6.7L engines. Use 68061633AA shell and filter. NOTE: The maintenance intervals for the fuel filter(s) is 15,000 miles, 400 engine hours or 12 Months, (whichever occurs first) or more often as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 3435 PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 3436 Fuel Filter: Technical Service Bulletins Fuel System - Severe Duty Filtration Kit Availability NUMBER: 14-001-09 GROUP: Fuel DATE: January 24, 2009 SUBJECT: Severe Duty Fuel Filtration Mopar Add On Kit Available MODELS: 2005 - 2009 (D1/DH) Ram Truck (2500/3500 Pick Up) 2007 - 2009 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH vehicles equipped with a 5.9L Cummins engine built from 2005 model year and D1/DH/DC vehicles equipped with a 6.7L Cummins engine built from 2007 model year. DISCUSSION: A frame mounted supplemental filter kit is now available for the vehicles listed above. This kit includes complete instructions (K6855569AC) with all necessary components and wiring to upgrade fuel filtering to a severe duty rating. NOTE: The maintenance intervals for the fuel filters (on engine filter and added chassis mounted severe duty fuel filtration kit filter) are 15,000 miles. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 3437 Fuel Filter: Technical Service Bulletins Diesel Fuel System - Fuel/Filtering Requirements NUMBER: 14-007-06 REV. A GROUP: Fuel DATE: September 02, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-007-06, DATED AUGUST 25, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL INFORMATION REGARDING FUELING OF EARLY BUILT 2007 RAM TRUCK CAB AND CHASSIS (DC) VEHICLES. SUBJECT: Fuel And Fuel Filtering Requirements For Cummins 5.9L And 6.7L Engines OVERVIEW: This bulletin involves a discussion regarding fuel system requirements. MODELS: 2006 - 2007 (DH/D1/DC) Ram Truck (Heavy Duty) NOTE: This bulletin applies to vehicles equipped with a 5.9L High Output or a 6.7L Cummins Turbo-Diesel Engine (sales codes ETH or ETJ respectively) that were built on or after March 07, 2006 (MDH 0307XX). DISCUSSION: Current Fuel Systems: - For the diesel engine system to operate at its peak performance a high level of fuel quality must be maintained. Emission control and fuel delivery systems have advanced significantly. Care must be taken to insure that the fuel that is delivered to the engine fuel injection system is of the highest quality possible and free of contaminants. - Significant components to fuel quality are: the initial quality of the fuel (as dispensed from the service station fuel pump or bulk storage), on-vehicle fuel storage, and the on-vehicle fuel filtering of the diesel fuel prior to the fuel injection process. - Refer to the Owners Manual for fuel and fuel system information. Proper Fuel And Fuel Quality: - Use good quality diesel fuel from a reputable supplier. It is recommended that purchase of diesel fuel should be made from a service station that is known to dispense a high volume of highway diesel fuel. - ** Ultra Low Sulfur Highway Diesel Fuel (15 ppm of sulfur or less and meeting ASTM D975 grade 5-15) is required for use in Dodge Ram Trucks equipped with a 6.7L diesel engine. ** - ** The 2007 Ram Truck Cab and Chassis (DC) vehicle is equipped with a 6.7L diesel engine. This vehicle is to use Ultra Low Sulfur Highway Diesel Fuel. Due to limited availability of Ultra Low Sulfur Highway Diesel Fuel, during the initial production of this vehicle, Low Sulfur Highway Diesel Fuel (500 ppm of sulfur or less) may be used ONLY until Ultra Low Sulfur Highway Diesel fuel becomes readily available and fuel pumps that dispense Ultra Low Sulfur Highway Diesel Fuel are required to be labelled as such. This is expected to occur around October 15, 2006. ** - ** Ultra Low Sulfur Highway Diesel Fuel (preferred) or Low Sulfur Highway Diesel Fuel (500 ppm of sulfur or less) are required for use in Dodge Ram Trucks equipped with a 5.9L diesel engine. ** - A maximum blend of 5% biodiesel (B5) is acceptable as long as the biodiesel mixture meets ASTM specification D-975, D-975 - grade 5-15, and ASTM D6751. A biodiesel fuel blend that is higher than 5% is not acceptable without additional fuel processing because these higher percentage biodiesel blends contain excess amounts of moisture which exceed the water stripping capability of the on-engine final fuel filter. Should a higher percentage biodiesel fuels be used an auxiliary water stripping filter will be required. - A maximum blend of 20% biodiesel (B20) can be used by government, military, and commercial fleets who equip their vehicle(s) with an optional water separator, and adhere to the guidelines in the Department of Defense specification A-A-59693 (in addition to: ASTM specification D-975, D-975 - grade 5-15 and ASTM D6751) - Off-highway diesel fuel (i.e. farm or marine use diesel fuel) that does not meet Ultra Low Sulfur Highway or Low Sulfur Highway fuel specifications (as listed above) is NOT acceptable. Unknown sulfur and water content and unknown cetane number may adversely affect the performance of the Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 3438 engine and fuel injection system. - Fuel conditioners (additives) are not recommended and should not be required if you buy good quality fuel and follow cold weather advice supplied in the Owners Manual. Proper Bulk (Off-Vehicle) Fuel Storage: - Proper maintenance of stored fuel is essential. Diesel fuel is seldom entirely free of moisture. Fuel contaminated with moisture may develop a bacteria or "slime" that may restrict or block fuel filters and lines. - As diesel fuel is lighter than water, drain condensation no less than monthly from the diesel fuel supply/storage tanks. - Change the storage tank in-line filter regularly. This filter acts as the last filter prior to the diesel fuel entering the vehicle diesel fuel tank. Good quality diesel fuel is mandatory. If the storage tank does not have an in-line filter, then a in-line filter should be added. Refer to the table on the following page for recommended in-line filter specifications. Proper On-vehicle Fuel Storage And Filtering: - Proper on-vehicle fuel storage that prevents fuel contamination is important. - The original (OEM) vehicle fuel tank module (fuel pickup) filter performs a primary filtering of the on-vehicle diesel fuel as the fuel leaves the fuel tank and enters the fuel lines. - On-vehicle auxiliary diesel fuel tanks are often added by the vehicle owner to extend vehicle driving range. Auxiliary fuel tank systems must protect the quality of the diesel fuel just as well as the originally equipped (OEM) fuel tank that came with the vehicle when it was new. - On-vehicle auxiliary diesel fuel storage tanks must have a primary fuel filter to prevent contamination and moisture accumulation. Refer to the table on the following page for recommended filter specifications. - The prevention of moisture in the fuel system, the prevention of fuel stagnation, and the use of a primary fuel filter should all be considered in the purchase, installation, and maintenance of any auxiliary on-vehicle diesel fuel tank. Proper On-vehicle Final Fuel Filtering: - The large fuel filter mounted at the engine is the final fuel filter, water separator, fuel heater, and water drain. This filter is the final 'line of defense" when maintaining a high level of fuel quality. If the diesel fuel is contaminated or contains moisture, the engine mounted fuel filter system is the last chance to affect possible correction. - The quality of the fuel, its prior storage, and fuel handling prior to the final filter all have a significant impact on the amount of contamination and moisture entering the final fuel filter. - It is important to drain accumulated moisture/water at least monthly from the final fuel filter. Do not wait until the 'Water In Fuel" indicator illuminates before performing this maintenance. - Maintenance on the final fuel filter / water separator is important. Follow the maintenance schedule per the Owners Manual. Replace the filter more frequently if highly contaminated or high moisture content fuel is encountered. - On a 5.9L engine, if the final fuel filter is replaced due to a high moisture content diesel fuel, verify that the water sensor probes in the final filter have been cleaned. Excessive moisture may contaminate the sensor sensing probes. The 6.7L engine includes a new water-in-fuel sensor with the new final fuel filter element. - The final fuel / water separator filter must meet or exceed OEM specifications. Some aftermarket filters may not meet OEM specifications. - The final fuel I water separator filter must meet or exceed the filtration specifications listed in the table shown. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 3439 - Final fuel / water separator filters that meet the above specifications are approved for use on Cummins 5.9L and 6.7L diesel engines. - The use of non-approved fuel filters will result in engine performance deterioration, and/or possible progressive damage to the engine from foreign particle ingestion, and/or fuel system component corrosion. - It is recommended that customers use the MOPAR approved or Cummins Equivalent fuel filters to protect the engine from debris and water contamination. - The following final fuel / water separator filters are known to meet or exceed the specifications listed in the table above. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Description and Operation > Description Fuel Filter: Description and Operation Description DESCRIPTION The fuel filter/water separator assembly is located on left side of engine above the starter motor. The assembly also includes the fuel heater, water drain valve, Water-In-Fuel (WIF) sensor and a quick-connect fittings attached at the side of the fuel filter canister. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Description and Operation > Description > Page 3442 Fuel Filter: Description and Operation Operation OPERATION The fuel filter/water separator protects the fuel injection pump by removing water and contaminants from the fuel. The construction of the filter/separator allows fuel to pass through it, but helps prevent moisture (water) from doing so. Moisture collects at the bottom of the filter. Refer to the maintenance schedules for the recommended fuel filter replacement intervals. For draining of water from canister, refer to Fuel/Water Separator Removal. There is a screened quick-connect fitting that is attached at the side of the fuel filter canister. It provides additional filtering for the high pressure fuel system components. A Water-In-Fuel (WIF) sensor is attached to the bottom of fuel filter element. The fuel heater is installed into the side of the filter/separator housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal Fuel Filter: Service and Repair Removal REMOVAL Refer to maintenance schedules for recommended fuel filter replacement intervals. Draining water from fuel filter canister: The housing drain valve (3) serves two purposes. One is to partially drain the filter housing of excess water. The other is to partially drain the housing for fuel filter or heater element replacement. The filter housing (1) should be partially drained whenever the water-in-fuel warning lamp remains illuminated. (Note that lamp will be illuminated for approximately two seconds when ignition key is initially placed in ON position for a bulb check). 1. A drain hose (4) is located at the bottom of drain valve. Place drain pan under drain hose. 2. With engine not running, rotate drain valve (3) approximately two revolutions to open it. Leave open until all water and contaminants have been removed and clean fuel exits. Hand tighten drain valve after tightening. 3. If fuel heater element is being replaced, drain housing completely. Dispose of mixture in drain pan according to applicable regulations. 4. After draining operation, close and tighten drain valve (3). 5. Fuel Filter Replacement: a. Remove left front tire/wheel. b. Remove left front wheel splash shield. c. Clean all debris from around filter canister (1) and canister head. d. Disconnect WIF sensor electrical connector (5). e. Open drain valve (3) two complete revolutions. Drain approximately 1 cup of fuel into a waste canister. Dispose of fuel according to environmental regulations. f. Remove drain hose (4) from drain valve (3). g. Use an oil filter type wrench to loosen filter (1). Continue removing filter by hand. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 3445 6. After fuel filter removal, also check and clean secondary filter screen. Press button (2) on quick-connect fitting. Disconnect fitting (1) from fitting (3). Unscrew fitting (3) from canister head to expose screen. 7. Clean screen (5) and check condition of O-ring (6). 8. Water-In-Fuel (WIF) Sensor Replacement: The WIF sensor (2) is located on the bottom of the fuel filter housing. The WIF sensor is not a separately serviceable item. If diagnostics have led you to replace this sensor, then the whole fuel filter assembly (1) needs to be changed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 3446 9. Fuel Heater Element Replacement: The heater element (2) is located in the fuel filter housing (4). a. Drain fuel filter. See previous steps. b. Disconnect electrical connector (1). c. Remove two mounting screws (3). d. Remove fuel heater (2). 10. Check condition of fuel heater O-ring (2). 11. Drain Valve Replacement: The Drain Valve is located on the bottom of the fuel filter. This is not a separately serviceable item. If replacement is necessary, replace the entire filter/filter canister assembly. 12. Fuel Filter Head (Housing) Replacement: a. If equipped, remove transmission dipstick tube from filter housing. b. Remove all low-pressure fuel lines at filter housing c. Remove housing from cylinder head. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 3447 Fuel Filter: Service and Repair Installation INSTALLATION Refer to maintenance schedules for recommended fuel filter replacement intervals. 1. Fuel Filter: CAUTION: Do not pre-fill the fuel filter with fuel. Severe damage to fuel system and injection system components may result. a. The engine has a self-priming low-pressure fuel system. b. Lubricate new fuel filter O-ring with clean engine oil. c. Position new fuel filter/canister assembly (1) to housing. d. Rotate fuel filter/canister assembly (1) until it comes to a hard stop. e. Tighten the filter element an additional half-inch of rotation. f. Connect WIF sensor electrical connector (5). g. Attach drain hose (4) to drain valve (3). h. Install left front tire/wheel. i. Install left front wheel splash shield. 2. Clean screen (5). 3. Check condition of new O-ring (6) and lubricate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 3448 4. Install screen assembly into housing and tighten fitting (3) to 20 ft. lbs. (27 Nm). 5. Connect quick connect fuel supply line (1) to fitting (3). 6. Fuel Heater Element: a. Check condition of O-ring (2). b. Lubricate new element O-ring before installation. 7. Install fuel heater element (3) into fuel filter housing (4). 8. Install two fuel heater mounting screws (3) and tighten to 60 in lbs. (6.8 Nm). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 3449 9. Connect electrical connector (1). 10. Fuel Filter Head (Housing): a. Install fuel filter head to cylinder head. Tighten bolts to 32 Nm (24 ft. lbs.) torque. b. Replace sealing washers on banjo bolts and install all low-pressure fuel lines to filter housing. Tighten banjo bolts to 24 Nm (18 ft. lbs.) torque. Tighten quick-connect fitting to 27 Nm (20 ft. lbs.) torque. c. If equipped, install transmission dipstick tube to filter housing. Tighten bolt to 10 Nm (8 ft. lbs.) torque. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications DESCRIPTION The cylinder block is constructed of cast iron. The casting is a skirted design which incorporates longitudal ribs for superior strength and noise reduction. The block incorporates metric straight thread o-ring fittings at lubrication oil access points. The engine is manufactured with the cylinders being a non-sleeved type cylinder. The cylinders are numbered front to rear ; 1 to 6. The firing order is 1-5-3-6-2-4. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > System Information > Specifications Ignition Timing: Specifications IGNITION TIMING Ignition timing is not adjustable on any engine. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure (Minimum) ...................................................................................................... ...................................................................... 350 psi. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3459 Compression Check: Testing and Inspection CYLINDER COMPRESSION/LEAKAGE TESTS CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure batteries are completely charged and the engine starter motor is in good operating condition. Otherwise, the indicated compression pressures may not be valid for diagnostic purposes. 1. Disconnect the fuel inlet line to the fuel filter housing. Plug the fuel line from the fuel tank. NOTE: Failure to plug fuel line will result in fuel leak. 2. Remove fuel transfer pump relay from PDC. 3. Start the engine and idle until the engine stalls (runs out of fuel). 4. Remove the cylinder head cover. 5. Remove the cylinder head cover carrier gasket. 6. Remove the high pressure fuel line between the cylinder head and fuel rail for the cylinder to be tested. Use tool 9864 to cap this fuel rail on the cylinder being tested. 7. Remove the fuel connector tube nut and fuel connector tube. 8. Remove the exhaust rocker lever. 9. Use Tool 9010 to remove the injector and copper sealing washer. 10. Install the exhaust rocker lever and torque to 36 Nm (27 ft. lbs.). 11. Cover the remaining rocker levers with clean shop towels to prevent any oil splatter under the hood. 12. Place a rag over the compression test tool fitting. Crank the engine for 2-3 seconds to purge any fuel that may have drained into the cylinder when the injector was removed. 13. Connect the compression test gauge. 14. Crank the engine for 5 seconds and record the pressure reading. Repeat this step three times and calculate the average of the three readings. NOTE: The minimum cylinder pressure is 350 psi. Cylinder pressure should be within 20% from cylinder to cylinder. 15. Combustion pressure leakage can be checked if cylinder pressure is below the specification. Perform the leakage test procedure on each cylinder according to the tester manufacturer instructions. 16. Upon completion of the test check and erase any engine related fault codes. CYLINDER COMBUSTION PRESSURE LEAKAGE The combustion pressure leakage test provides an accurate means for determining engine condition. Combustion pressure leakage testing will detect: - Exhaust and intake valve leaks (improper seating). - Leaks between adjacent cylinders or into water jacket. - Any causes for combustion/compression pressure loss 1. Start and operate the engine until it attains normal operating temperature. 2. Disconnect injector harness connectors. 3. Disconnect CCV tube and breather drain tube from valve cover. 4. Remove the cylinder head cover. 5. Disconnect harness from injectors. 6. Remove the cylinder head cover carrier gasket. 7. Bring the cylinder to be tested to TDC. 8. Remove the high pressure fuel line between the cylinder head and the fuel rail for the cylinder to be tested. 9. Install capping Tool 9864 onto the rail. 10. Remove the high pressure connector nut and high pressure connector with Tool 9015. 11. Remove the exhaust and intake rocker lever. 12. Use Tool # 9010 to remove the injector and copper sealing washer. 13. Install compression test Tool # 9007 into the injector bore. 14. Connect the leakage tester and perform the leakage test procedure on each cylinder according to the tester manufacturer's instructions. 15. Upon completion of the test check and erase any engine related fault codes. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments VALVE LASH ADJUSTMENT AND VERIFICATION NOTE: To obtain accurate readings, valve lash measurements AND adjustments should only be performed when the engine coolant temperature is less than 60°C (140°F). The 24-valve overhead system is a "low-maintenance" design. Routine adjustments are no longer necessary, however, measurement should still take place when troubleshooting performance problems, or upon completion of a repair that includes removal and installation of the valve train components or injectors. 1. Disconnect battery negative cables. 2. Remove cylinder head cover. 3. Using the crankshaft barring tool #7471-B, rotate crankshaft to align damper TDC mark to 12:00 o'clock position. a. If both number one cylinder rocker levers are loose, continue to next step. b. If both number one cylinder rocker levers are not loose, rotate crankshaft 360 degrees. 4. With the engine in this position, valve lash can be measured at the following rocker arms: INTAKE 1-2-4 / EXHAUST 1-3-5. Measure the valve lash by inserting a feeler gauge between the rocker arm socket and crosshead. Refer to VALVE LASH LIMIT CHART for the correct specifications. If the measurement falls within the limits, adjustment/resetting is not necessary. If measurement finds the lash outside of the limits, adjustment/resetting is required. Valve Lash Limit Chart Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > Page 3463 5. If adjustment/resetting is required, loosen the lock nut on rocker arms and turn the adjusting screw until the desired lash is obtained: - INTAKE 0.254 mm (0.010 in.) - EXHAUST 0.660 mm (0.026 in.) Tighten the lock nut to 24 Nm (18 ft. lbs.) and recheck the valve lash. 6. Using the crankshaft barring tool, rotate the crankshaft one revolution (360°) to align the damper TDC mark to the 12 o'clock position. 7. With the engine in this position, valve lash can be measured at the remaining rocker arms: INTAKE 3-5-6 / EXHAUST 2-4-6. Use the same method as above for determining whether adjustment is necessary, and adjust those that are found to be outside of the limits. 8. Install the cylinder head cover. 9. Connect the battery negative cables. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Install water pump with the weep hole facing downward. Tighten mounting bolts to ............................................................................. 24 Nm (18 ft. lbs.) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description and Operation > Water Pump Water Pump: Description and Operation Water Pump Description WATER PUMP A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core. The pump is driven from the engine crankshaft by a single serpentine drive belt. The water pump impeller is pressed onto the rear of a shaft that rotates in bearings pressed into the housing. The housing has two small holes to allow seepage to escape. The water pump seals are lubricated by the antifreeze in the coolant mixture. No additional lubrication is necessary. Operation WATER PUMP A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core, this coolant absorbs the heat generated when the engine is running. The pump is driven by the engine crankshaft via a drive belt. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description and Operation > Water Pump > Page 3469 Water Pump: Description and Operation Water Pump Bypass Description WATER PUMP BYPASS The 3.7L and 4.7L engine uses an internal water/coolant bypass system. The design uses galleries in the timing chain cover to circulate coolant during engine warm-up preventing the coolant from flowing through the radiator. Operation - 3.7L/4.7L WATER PUMP BYPASS - 3.7L/4.7L When the thermostat is in the closed position the bypass gallery is not obstructed allowing 100% flow. When the thermostat is in the open position the pill partially covers the bypass hole, reducing the amount of bypass flow. This design allows the coolant to reach operating temperature quickly when cold, while adding extra cooling during normal temperature operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description and Operation > Page 3470 Water Pump: Testing and Inspection WATER PUMP A quick test to determine if pump is working is to check if heater warms properly. A defective water pump will not be able to circulate heated coolant through the long heater hose to the heater core. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures Water Pump: Procedures Cleaning CLEANING Clean the gasket mating surface. Use caution not to damage the gasket sealing surface. Inspection INSPECTION Inspect the water pump assembly for cracks in the housing, water leaks from shaft seal, worn bearing or impeller rubbing either the pump body or timing chain case/cover. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 3473 Water Pump: Removal and Replacement Removal 5.9L/6.7L DIESEL 1. Disconnect battery negative cables. 2. Drain cooling system. 3. Disconnect ambient air temp sensor electrical connector and mass airflow sensor electrical connector (if equipped). 4. Remove turbocharger inlet tube and air filter housing. 5. Remove generator assembly. 6. Remove the accessory drive belt. 7. Remove water pump mounting bolts (3). 8. Remove O-ring from water pump. 9. Clean water pump sealing surface on cylinder block. Installation 5.9L/6.7L DIESEL 1. Install new O-ring seal in groove on water pump. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 3474 2. Install water pump with the weep hole facing downward. Tighten mounting bolts to 24 Nm (18 ft. lbs.) torque. 3. Install generator assembly. 4. Install accessory drive belt. 5. Install air box and tube assembly. 6. Install air filter housing. 7. Fill cooling system. 8. Connect both battery cables. 9. Start and warm the engine. Check for leaks. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Coolant: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 3480 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications ENGINE COOLANT Capacity ............................................................................................................................................... ...................................... * 21.4 liters (22.6 quarts) * Includes 0.9 liters (1.0 quarts) for coolant reservoir. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 3483 Coolant: Fluid Type Specifications ENGINE COOLANT Mopar Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Organic Additive Technology) or equivalent. NOTE: 50/50 Ethylene-Glycol and Distilled Water is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation. maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67°C (-90° F). A higher percentage will freeze in warmer temperature. Also a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. NOTE: This coolant offers the best engine cooling without corrosion when mixed with 50% Ethylene-Glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it looses color or becomes contaminated, drain, flush and replace with fresh properly mixed coolant solution. CAUTION: Do not use coolant additives that are claimed to improve cooling. CAUTION: Mopar Antifreeze/Coolant, 5 year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified non-HOAT or other HOAT coolant, may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Description Coolant: Description and Operation Description Coolant COOLANT WARNING: Antifreeze is an ethylene glycol base coolant and is harmful if swallowed or inhaled. If swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area. Seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene glycol. Keep out of reach of children. Dispose of glycol base coolant properly, contact your dealer or government agency for location of collection center in your area. Do not open a cooling system when the engine is at operating temperature or hot under pressure, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. ETHYLENE-GLYCOL MIXTURES CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar(R) Antifreeze/Coolant, 5 Year 100,000 Mile Formula (ethylene-glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain a freeze point of -37°C (-35°F). The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower than 44 percent, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68% antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22°C (-8°F). PROPYLENE-GLYCOL MIXTURES It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32°C (-26°F). 5° C higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of propylene-glycol is 125°C (257°F) at 96.5 kPa (14 psi), compared to 128°C (263°F) for ethylene-glycol. Use of propylene-glycol can result in boil-over or freeze-up on a cooling system designed for ethylene-glycol. Propylene- glycol also has poorer heat transfer characteristics than ethylene-glycol. This can increase cylinder head temperatures under certain conditions. Propylene-glycol/ethylene-glycol Mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the various cooling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining freeze point will not be accurate. Both the refractive index and specific gravity differ between ethylene glycol and propylene-glycol. HOAT Coolant HOAT COOLANT WARNING: Antifreeze is an ethylene-glycol base coolant and is harmful if swallowed or inhaled. If swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area. Seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene-glycol. Keep out of reach of children. Dispose of glycol base coolant properly, contact your dealer or government agency for location of collection center in your area. Do not open a cooling system when the engine is at operating temperature or hot under pressure, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene-glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Description > Page 3486 Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. COOLANT PERFORMANCE The required ethylene-glycol and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows: Pure Water- Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F). 50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. COOLANT SELECTION AND ADDITIVES The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain a freeze point of -37 °C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Do not use coolant additives that are claimed to improve engine cooling. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Description > Page 3487 Coolant: Description and Operation Operation OPERATION Coolant flows through the engine block, cylinder head, absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere. On the 6.7L diesel engine, coolant also flows through the EGR cooler and turbocharger actuator. During cold weather the ethylene-glycol or propylene-glycol coolant prevents water present in the cooling system from freezing within temperatures indicated by mixture ratio of coolant to water. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Page 3488 Coolant: Testing and Inspection COOLANT CONCENTRATION TESTING Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37°C (-34°F) to -46°C (-50°F). The use of a hydrometer or Tool 8266, refractometer can be used to test coolant concentration. A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and higher the freeze protection (up to a maximum of 60% by volume glycol). A Refractometer Tool 8286 will test the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufactures use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and is not recommended. CAUTION: Do not mix types of coolant - corrosion protection will be severely reduced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation > Description Coolant Reservoir: Description and Operation Description DESCRIPTION The coolant reserve/overflow tank is mounted on top of the fan shroud, and is made of high temperature plastic. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation > Description > Page 3493 Coolant Reservoir: Description and Operation Operation OPERATION The coolant reserve/overflow system works in conjunction with the radiator pressure cap. It utilizes thermal expansion and contraction of coolant to keep coolant free of trapped air. It provides a volume for expansion and contraction of coolant. It also provides a convenient and safe method for checking coolant level and adjusting level at atmospheric pressure. This is done without removing the radiator pressure cap. The system also provides some reserve coolant to the radiator to cover minor leaks and evaporation or boiling losses. As the engine cools, a vacuum is formed in the cooling system of both the radiator and engine. Coolant will then be drawn from the coolant tank and returned to a proper level in the radiator. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Removal Coolant Reservoir: Service and Repair Removal 5.9L/6.7L DIESEL 1. Remove overflow hose (5) from radiator (1) 2. Remove mounting bolts (4). 3. Remove coolant recovery bottle (2) from bracket (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Removal > Page 3496 Coolant Reservoir: Service and Repair Installation 5.9L/6.7L DIESEL 1. Position coolant recovery bottle (2) on bracket (3). 2. Install mounting bolts (4). Tighten to 8.5 Nm (75 in. lbs). 3. Install overflow hose (5) onto radiator (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Locations Radiator Cooling Fan Control Module: Locations Component ID: 80 Component : DRIVE-FAN-RADIATOR Connector: Name : DRIVE-FAN-RADIATOR Color : DK. GRAY # of pins : 6 Qualifier : (DIESEL) Gender : FEMALE Pin Description Circuit 1 PWM FAN COIL SIGNAL K160 18BR/OR Pin Description Circuit 1 SENSOR GROUND K971 18BR/PK 2 FAN SPEED SENSOR SIGNAL N210 18DB/DG 2 SENSOR GROUND K916 18BR/OR 3 FAN SPEED SENSOR GROUND K161 18BR/LB 3 FAN SPEED SENSOR SIGNAL N27 18DB/GY 4-5 5 VOLT SUPPLY K668 18BR 5 5 VOLT SUPPLY F855 18PK/YL 6 FUSED B(+) A212 18PK/YL 6 FAN SPEED SENSOR GROUND K161 18BR/LB Component Location - 37 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3501 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3502 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3503 Radiator Cooling Fan Control Module: Diagrams Component ID: 80 Component : DRIVE-FAN-RADIATOR Connector: Name : DRIVE-FAN-RADIATOR Color : DK. GRAY # of pins : 6 Qualifier : (DIESEL) Gender : FEMALE Pin Description Circuit 1 PWM FAN COIL SIGNAL K160 18BR/OR Pin Description Circuit 1 SENSOR GROUND K971 18BR/PK 2 FAN SPEED SENSOR SIGNAL N210 18DB/DG 2 SENSOR GROUND K916 18BR/OR 3 FAN SPEED SENSOR GROUND K161 18BR/LB 3 FAN SPEED SENSOR SIGNAL N27 18DB/GY 4-5 5 VOLT SUPPLY K668 18BR 5 5 VOLT SUPPLY F855 18PK/YL 6 FUSED B(+) A212 18PK/YL 6 FAN SPEED SENSOR GROUND K161 18BR/LB Component Location - 37 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3504 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3505 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3510 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3511 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3512 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3513 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3514 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3515 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3516 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3517 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3518 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3519 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3520 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3521 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3522 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3523 Radiator Cooling Fan Motor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3524 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3525 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3526 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3527 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Customer Interest for Fan Clutch: > 07-003-10 > Sep > 10 > Engine Controls - ECM Update for Fan Clutch Operation Fan Clutch: Customer Interest Engine Controls - ECM Update for Fan Clutch Operation NUMBER: 07-003-10 GROUP: Cooling DATE: September 09, 2010 SUBJECT: High Coolant Temperatures On Vehicles Equipped With Snow Plows OVERVIEW: This bulletin provides information on how to program the Engine Control Module (ECM) to force the fan clutch to fully engage at all operating conditions MODELS: 2007 - 2010 DC/DM Ram 3500/4500/5500 Cab Chassis Trucks 2011 DD/DP Ram 3500/4500/5500 Cab Chassis Trucks NOTE: This bulletin applies to vehicles equipped with the 6.7L Cummins Diesel engine (Sales Code ETJ) DISCUSSION: Customers that operate their vehicle with a snowplow attached to the vehicle may cause the airflow passing through the radiator to be disrupted resulting in higher than normal engine temperatures The 6~7L Cummins ECM is equipped with software that can fully engage the fan clutch to allow an increase of airflow through the radiator Customers can initiate the fan clutch operation by performing the following button sequence NOTE: 2007 early 2009 models were not originally equipped with the fan clutch software however, recently released software does include this enhancement Ensure that the ECM software is at the latest level and if not, flash the ECM Refer to Service Bulletin 18-020-10 for additional information 1. Turn the ignition key to the run position or start the truck 2. Simultaneously press and release the Cruise Control "Cancel" button/lever and the "Exhaust Brake" button. Repeat this sequence four times within five seconds. The chime will sound twice as an audible indicator that the function is engaged 3. To disable the function, repeat the same procedure The chime will sound four times as an audible indicator that the function is disengaged NOTE: Customer's should be made aware that an increase in fan noise and a decrease in fuel economy may result when using this feature. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fan Clutch: > 07-003-10 > Sep > 10 > Engine Controls - ECM Update for Fan Clutch Operation Fan Clutch: All Technical Service Bulletins Engine Controls - ECM Update for Fan Clutch Operation NUMBER: 07-003-10 GROUP: Cooling DATE: September 09, 2010 SUBJECT: High Coolant Temperatures On Vehicles Equipped With Snow Plows OVERVIEW: This bulletin provides information on how to program the Engine Control Module (ECM) to force the fan clutch to fully engage at all operating conditions MODELS: 2007 - 2010 DC/DM Ram 3500/4500/5500 Cab Chassis Trucks 2011 DD/DP Ram 3500/4500/5500 Cab Chassis Trucks NOTE: This bulletin applies to vehicles equipped with the 6.7L Cummins Diesel engine (Sales Code ETJ) DISCUSSION: Customers that operate their vehicle with a snowplow attached to the vehicle may cause the airflow passing through the radiator to be disrupted resulting in higher than normal engine temperatures The 6~7L Cummins ECM is equipped with software that can fully engage the fan clutch to allow an increase of airflow through the radiator Customers can initiate the fan clutch operation by performing the following button sequence NOTE: 2007 early 2009 models were not originally equipped with the fan clutch software however, recently released software does include this enhancement Ensure that the ECM software is at the latest level and if not, flash the ECM Refer to Service Bulletin 18-020-10 for additional information 1. Turn the ignition key to the run position or start the truck 2. Simultaneously press and release the Cruise Control "Cancel" button/lever and the "Exhaust Brake" button. Repeat this sequence four times within five seconds. The chime will sound twice as an audible indicator that the function is engaged 3. To disable the function, repeat the same procedure The chime will sound four times as an audible indicator that the function is disengaged NOTE: Customer's should be made aware that an increase in fan noise and a decrease in fuel economy may result when using this feature. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Description Coolant Temperature Sensor/Switch (For Computer): Description and Operation Description DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Description > Page 3546 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Operation OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air-fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: - for engine coolant temperature gauge operation through CAN Bus communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid on/off times - Cooling fan control - Temperature gauge operation - A/C cutoff at high coolant temperatures - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Removal Coolant Temperature Sensor/Switch (For Computer): Service and Repair Removal 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL WARNING: Hot, pressurized coolant can cause injury by scalding. Cooling system must be partially drained before removing the coolant temperature sensor. 1. Partially drain the cooling system. ECT LOCATION - 5.9L DIESEL 2. Remove heat shield (if equipped). 3. Disconnect the electrical connector (2) from the ETC sensor (3). 4. Remove the ETC sensor from the cylinder head. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Removal > Page 3549 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Installation 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL 1. Install sensor (1 or 3) to engine. 2. Tighten sensor to 18 Nm (13 ft. lbs.) torque. ECT LOCATION - 5.9L DIESEL 3. Connect electrical connector (2) to ETC sensor (1 or 3). 4. Install heat shield (if equipped). 5. Replace any lost engine coolant. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Description Heater Core: Description and Operation Description DESCRIPTION The heater core (1) is a heat exchanger made of rows of tubes and fins. The heater core is positioned within the HVAC housing through the panel (2) located at the front of the HVAC housing. The heater core tubes (3) are attached to the front of the heater core and are secured to the HVAC housing by a bracket. The heater core can be serviced by removing the HVAC housing assembly from the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Description > Page 3554 Heater Core: Description and Operation Operation OPERATION Engine coolant is circulated through the heater hoses to the heater core at all times. As the coolant flows through the heater core, heat is removed from the engine and is transferred to the heater core tubes and fins. Air directed through the heater core picks up the heat from the heater core fins. The blend-air door(s) allows control of the heater output air temperature by regulating the amount of air flowing through the heater core. The blower motor speed controls the volume of air flowing through the HVAC housing. The heater core cannot be repaired and must be replaced if restricted, leaking or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Installation Heater Core: Service and Repair Installation INSTALLATION 1. Carefully install the heater core (3) into the front of the HVAC housing. 2. Position the heater core tube bracket (2) onto the HVAC housing. 3. Install the two screws (1) that secure the heater core bracket to the HVAC housing. Tighten the screws to 1.1 Nm (10 in. lbs.). 4. If equipped with the dual zone heating-A/C system, install the linkage rod (4). 5. Install the foam seal onto the heater core tubes. NOTE: If the heater core is being replaced, flush the cooling system. 6. Install the HVAC housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Installation > Page 3557 Heater Core: Service and Repair Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. NOTE: Disassembly of the HVAC housing is not required to remove heater core. 1. Remove the HVAC housing. 2. Remove the foam seal from the heater core tubes. 3. If equipped with the dual zone heating-A/C system, remove the linkage rod (4) to gain access to the heater core (3). 4. Remove the two screws (1) that secure the heater core tube bracket (2) to the HVAC housing and remove the bracket. 5. Carefully pull the heater core out of the front of the HVAC housing. 6. Inspect all foam seals and replace as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation > Description Temperature Gauge: Description and Operation Description DESCRIPTION An engine coolant temperature gauge is standard equipment on all instrument clusters. The engine coolant temperature gauge is located in the lower right quadrant of the instrument cluster, below the oil pressure gauge. The gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from C (or Cold) to H (or Hot) for gasoline engines. On vehicles with a diesel engine, the scale reads from 60° C to 120° C in markets where a metric instrument cluster is specified, or from 140° F to 245° F in all other markets. An International Control and Display Symbol icon for Engine Coolant Temperature is located on the cluster overlay, directly below the left end of the gauge scale. The engine coolant temperature gauge graphics are black against a white field except for a single red graduation at the high end of the gauge scale making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the black gauge graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The engine coolant temperature gauge is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation > Description > Page 3563 Temperature Gauge: Description and Operation Operation OPERATION The engine coolant temperature gauge gives an indication to the vehicle operator of the engine coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Controller Area Network (CAN) data bus. The engine coolant temperature gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Temperature Message - Each time the cluster receives an electronic engine temperature message from the PCM or ECM indicating the temperature is between the low end of normal about 54° C (130° F) for gasoline engines, or about 60° C (140° F) for diesel engines] and the high end of normal about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines], the gauge needle is moved to the actual relative temperature position on the gauge scale. - Engine Temperature Low Message - Each time the cluster receives an electronic engine temperature message from the PCM or ECM indicating the temperature is below the low end of normal about 54° C (130° F) for gasoline engines, or about 60° C (140° F) for diesel engines], the gauge needle is held at the graduation on the far left end of the gauge scale. The gauge needle remains at the low end of the gauge scale until the cluster receives a message from the PCM or ECM indicating the temperature is above about 54° C (130° F) for gasoline engines, or about 60° C (140° F) for diesel engines, or until the ignition switch is turned to the OFF position, whichever occurs first. - Engine Temperature High Message - Each time the cluster receives three consecutive electronic engine temperature messages from the PCM or ECM indicating the temperature is above about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, the gauge needle is moved to the red increment or zone at the far right end of gauge scale, the check gauges indicator is illuminated, and a single chime tone is sounded. The gauge needle remains at the high end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the temperature is below about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the check gauges indicator is cycled OFF and then ON again by the appropriate messages from the PCM or ECM. - Communication Error - If the cluster fails to receive an engine temperature message, it will hold the gauge needle at the last indication for about 10 seconds or until the ignition switch is turned to the OFF position, whichever occurs first. After 10 seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the engine coolant temperature gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM (gasoline engine) or ECM (diesel engine) continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM or ECM then sends the proper messages to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the engine coolant temperature gauge or the instrument cluster circuitry that controls the gauge refer to Instrument Cluster/Carrier Testing. If the instrument cluster turns ON the check gauges indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. For proper diagnosis of the engine coolant temperature sensor, the PCM, the ECM, the EMIC, the CAN data bus or the electronic communication related to engine coolant temperature gauge operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation > Description Radiator: Description and Operation Description DESCRIPTION The radiator is a aluminum cross-flow design with horizontal tubes through the radiator core and vertical plastic side tanks. This radiator does not contain an internal transmission oil cooler. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation > Description > Page 3568 Radiator: Description and Operation Operation OPERATION The radiator supplies sufficient heat transfer using the cooling fins interlaced between the horizontal tubes in the radiator core to cool the engine. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation > Page 3569 Radiator: Testing and Inspection RADIATOR COOLANT FLOW Use the following procedure to determine if coolant is flowing through the cooling system. 1. Idle engine until operating temperature is reached. If the upper radiator hose is warm to the touch, the thermostat is opening and coolant is flowing to the radiator. WARNING: Hot, pressurized coolant can cause injury by scalding. Using a rag to cover the radiator pressure cap, open radiator cap slowly to the first stop. This will allow any built-up pressure to vent to the reserve/overflow tank. After pressure build-up has been released, remove cap from filler neck. 2. Drain a small amount of coolant from the radiator until the ends of the radiator tubes are visible through the filler neck. Idle the engine at normal operating temperature. If coolant is flowing past the exposed tubes, the coolant is circulating. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures Radiator: Procedures Cleaning CLEANING Clean radiator fins are necessary for good heat transfer. The radiator and oil cooler fins should be cleaned when an accumulation of debris has occurred. With the engine cold, apply cold water and compressed air to the back (engine side) of the radiator to flush the radiator and/or oil coolers of debris. Inspection INSPECTION Inspect the radiator side tanks for cracks, and broken or missing fittings. Inspect the joint where the tanks seam up to the radiator core for signs of leakage and/or deteriorating seals. Inspect radiator core for corroded, bent or missing cooling fins. Inspect the core for bent or damaged cooling tubes. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 3572 Radiator: Removal and Replacement Removal 5.9L/6.7L DIESEL 1. Disconnect both battery negative cables. WARNING: Do not remove the cylinder block drain plugs or loosen the radiator draincock with the system hot and under pressure. Serious burns from coolant can occur. 2. Drain the cooling system. 3. Disconnect ambient air temperature sensor electrical connector and mass airflow sensor electrical connector (If equipped). 4. Remove air box and turbocharger inlet tube. 5. Remove coolant tank hose, washer bottle hose and the positive battery cable from the fastening clips located on top of the radiator. 6. Remove hose clamps and hoses from radiator. 7. Remove fan shroud mounting nuts from mounting brackets. 8. Pull shroud toward front of vehicle to clear mounting brackets 9. Turn shroud slightly and push toward engine to gain clearance for radiator. 10. Remove the power steering cooler mounting bolts and position the power steering cooler out of the way. 11. Disconnect the transmission cooler lines at the transmission cooler. The transmission cooler will remain on the radiator and can be removed as an assembly. 12. Remove the two radiator upper mounting bolts. 13. Tilt radiator toward front of vehicle and lift out of engine compartment. The bottom of the radiator is equipped with two alignment dowels that fit into holes in the lower radiator support panel. Rubber biscuits (insulators) are installed to these dowels. Take care not to damage cooling fins or tubes on the radiator and air conditioning condenser or the electronic viscous fan connector when removing. Installation 5.9L/6.7L DIESEL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 3573 1. Install rubber insulators to alignment dowels at lower part of radiator. 2. Lower the radiator into position while guiding the two alignment dowels into lower radiator support. Different alignment holes are provided in the lower radiator support for each engine application. 3. Install two upper radiator mounting bolts. Tighten bolts to 12 Nm (105 in. lbs.) torque. 4. Connect both radiator hoses and install hose clamps. 5. If equipped, connect transmission cooler lines to transmission cooler. Inspect quick connect fittings for debris and install until an audible "click" is heard. Tug on lines to verify connection. 6. Position power steering cooler on the radiator and tighten nuts to 10 Nm (90 in. lbs.) 7. Position fan shroud on brackets. 8. Install fan shroud mounting nut. Tighten nut to 24 Nm (18 ft. lbs.). 9. Install the coolant recovery container. 10. Position coolant recovery tank hose, washer bottle hose and the positive battery cable into the clips located on the top of the radiator. 11. Install air box and turbocharger inlet hose. Tighten clamps to 4 Nm (35 in. lbs.). 12. Connect mass airflow sensor electrical connector and ambient air temp sensor electrical connector (if equipped). 13. Position heater controls to full heat position. 14. Fill cooling system with coolant. 15. Operate engine until it reaches normal temperature. Check cooling system and automatic transmission (if equipped) fluid levels. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation > Description Radiator Cap: Description and Operation Description DESCRIPTION All cooling systems are equipped with a pressure cap. For all engines, the pressure cap is located on top of the radiator outlet tank. The cap releases pressure at some point within a range of 97-to-124 kPa (14-to-18 psi). The pressure relief point (in pounds) is engraved on top of the cap The cooling system will operate at pressures slightly above atmospheric pressure. This results in a higher coolant boiling point allowing increased radiator cooling capacity. The cap contains a spring-loaded pressure relief valve. This valve opens when system pressure reaches the release range of 97-to-124 kPa (14-to-18 psi). A rubber gasket seals the radiator filler neck. This is done to maintain vacuum during coolant cool-down and to prevent leakage when system is under pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation > Description > Page 3578 Radiator Cap: Description and Operation Operation OPERATION A vent valve in the center of the cap will remain shut as long as the cooling system is pressurized. As the coolant cools, it contracts and creates a vacuum in the cooling system. This causes the vacuum valve to open and coolant in the reserve/overflow container to be drawn through the recovery hose connecting the filler neck and reserve/overflow container. If the vacuum valve is stuck shut, or the recovery hose is kinked, radiator hoses will collapse on cool down. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Radiator Cap Radiator Cap: Testing and Inspection Radiator Cap RADIATOR CAP Remove the cap from the radiator. Be sure that the sealing surfaces are clean. Moisten the rubber gasket with water and install the cap on the pressure tester 7700 or an equivalent. Operate the tester pump to bring the pressure to 104 kPa (15 psi) on the gauge. If the pressure cap fails to hold pressure of at least 97 kPa (14 psi) replace the cap. Refer to the following CAUTION. The pressure cap may test properly while positioned on tool 7700 (or equivalent). It may not hold pressure or vacuum when installed on the radiator. If so, inspect the radiator filler neck and radiator cap's top gasket for damage. Also inspect for dirt or distortion that may prevent the cap from sealing properly. CAUTION: Radiator pressure testing tools are very sensitive to small air leaks which will not cause cooling system problems. A pressure cap that does not have a history of coolant loss should not be replaced just because it leaks slowly when tested with this tool. Add water to tool. Turn tool upside down and recheck pressure cap to confirm that cap needs replacement. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Radiator Cap > Page 3581 Radiator Cap: Testing and Inspection Radiator Cap To Filler Neck Seal RADIATOR CAP-TO-FILLER NECK SEAL The pressure cap upper gasket (seal) pressure relief can be tested by removing overflow hose from the radiator filler neck tube. Attach the hose of the pressure tester tool 7700 (or equivalent) to the tube. It will be necessary to disconnect hose from its adapter for the filler neck. Pump air into radiator. The pressure cap upper gasket should relieve at 69 to 124kPa (10 to 18 psi) and hold pressure at a minimum of 55 kPa (8 psi). WARNING: The warning words, "DO NOT OPEN HOT", on radiator pressure cap, are a safety precaution. When hot, pressure builds up in cooling system. To prevent scalding or injury, radiator cap should not be removed while system is hot and/or under pressure. Do not remove the radiator cap at any time except for the following purposes: - Check and adjust antifreeze freeze point. - Refill the system with new antifreeze. - Conducting service procedures. - Checking for vacuum leaks. WARNING: If vehicle has been run recently, wait at least 15 minutes before removing radiator cap. With a rag, squeeze radiator upper hose to check if system is under pressure. Place a rag over cap and without pushing cap down, rotate it counter-clockwise to first stop. Allow fluid to escape through the coolant reserve/overflow hose into reserve/overflow tank. Squeeze radiator upper hose to determine when pressure has been released. When coolant and steam stop being pushed into tank and system pressure drops, remove radiator cap completely. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Service and Repair > Cleaning Radiator Cap: Service and Repair Cleaning CLEANING Use only a mild soap and water to clean the radiator cap. Using any type of solvent may cause damage to the seal in the radiator cap. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Service and Repair > Cleaning > Page 3584 Radiator Cap: Service and Repair Inspection INSPECTION Hold cap at eye level, right side up. The vent valve at bottom of cap should closed. A slight downward pull on the vent valve should open it. If the rubber gasket has swollen and prevents vent valve from opening, replace cap. Hold cap at eye level, upside down. If any light can be seen between vent valve and rubber gasket, replace cap. A replacement cap must be the type designed for a coolant reserve/overflow system with a completely sealed diaphragm spring and a rubber gasket. This gasket is used to seal to radiator filler neck top surface. Use of proper cap will allow coolant return to radiator. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations Radiator Cooling Fan Control Module: Locations Component ID: 80 Component : DRIVE-FAN-RADIATOR Connector: Name : DRIVE-FAN-RADIATOR Color : DK. GRAY # of pins : 6 Qualifier : (DIESEL) Gender : FEMALE Pin Description Circuit 1 PWM FAN COIL SIGNAL K160 18BR/OR Pin Description Circuit 1 SENSOR GROUND K971 18BR/PK 2 FAN SPEED SENSOR SIGNAL N210 18DB/DG 2 SENSOR GROUND K916 18BR/OR 3 FAN SPEED SENSOR GROUND K161 18BR/LB 3 FAN SPEED SENSOR SIGNAL N27 18DB/GY 4-5 5 VOLT SUPPLY K668 18BR 5 5 VOLT SUPPLY F855 18PK/YL 6 FUSED B(+) A212 18PK/YL 6 FAN SPEED SENSOR GROUND K161 18BR/LB Component Location - 37 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3589 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3590 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3591 Radiator Cooling Fan Control Module: Diagrams Component ID: 80 Component : DRIVE-FAN-RADIATOR Connector: Name : DRIVE-FAN-RADIATOR Color : DK. GRAY # of pins : 6 Qualifier : (DIESEL) Gender : FEMALE Pin Description Circuit 1 PWM FAN COIL SIGNAL K160 18BR/OR Pin Description Circuit 1 SENSOR GROUND K971 18BR/PK 2 FAN SPEED SENSOR SIGNAL N210 18DB/DG 2 SENSOR GROUND K916 18BR/OR 3 FAN SPEED SENSOR GROUND K161 18BR/LB 3 FAN SPEED SENSOR SIGNAL N27 18DB/GY 4-5 5 VOLT SUPPLY K668 18BR 5 5 VOLT SUPPLY F855 18PK/YL 6 FUSED B(+) A212 18PK/YL 6 FAN SPEED SENSOR GROUND K161 18BR/LB Component Location - 37 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3592 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3593 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Description Coolant Temperature Sensor/Switch (For Computer): Description and Operation Description DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Description > Page 3600 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Operation OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air-fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: - for engine coolant temperature gauge operation through CAN Bus communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid on/off times - Cooling fan control - Temperature gauge operation - A/C cutoff at high coolant temperatures - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Removal Coolant Temperature Sensor/Switch (For Computer): Service and Repair Removal 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL WARNING: Hot, pressurized coolant can cause injury by scalding. Cooling system must be partially drained before removing the coolant temperature sensor. 1. Partially drain the cooling system. ECT LOCATION - 5.9L DIESEL 2. Remove heat shield (if equipped). 3. Disconnect the electrical connector (2) from the ETC sensor (3). 4. Remove the ETC sensor from the cylinder head. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Removal > Page 3603 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Installation 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL 1. Install sensor (1 or 3) to engine. 2. Tighten sensor to 18 Nm (13 ft. lbs.) torque. ECT LOCATION - 5.9L DIESEL 3. Connect electrical connector (2) to ETC sensor (1 or 3). 4. Install heat shield (if equipped). 5. Replace any lost engine coolant. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation > Description Temperature Gauge: Description and Operation Description DESCRIPTION An engine coolant temperature gauge is standard equipment on all instrument clusters. The engine coolant temperature gauge is located in the lower right quadrant of the instrument cluster, below the oil pressure gauge. The gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from C (or Cold) to H (or Hot) for gasoline engines. On vehicles with a diesel engine, the scale reads from 60° C to 120° C in markets where a metric instrument cluster is specified, or from 140° F to 245° F in all other markets. An International Control and Display Symbol icon for Engine Coolant Temperature is located on the cluster overlay, directly below the left end of the gauge scale. The engine coolant temperature gauge graphics are black against a white field except for a single red graduation at the high end of the gauge scale making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the black gauge graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The engine coolant temperature gauge is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation > Description > Page 3608 Temperature Gauge: Description and Operation Operation OPERATION The engine coolant temperature gauge gives an indication to the vehicle operator of the engine coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Controller Area Network (CAN) data bus. The engine coolant temperature gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Temperature Message - Each time the cluster receives an electronic engine temperature message from the PCM or ECM indicating the temperature is between the low end of normal about 54° C (130° F) for gasoline engines, or about 60° C (140° F) for diesel engines] and the high end of normal about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines], the gauge needle is moved to the actual relative temperature position on the gauge scale. - Engine Temperature Low Message - Each time the cluster receives an electronic engine temperature message from the PCM or ECM indicating the temperature is below the low end of normal about 54° C (130° F) for gasoline engines, or about 60° C (140° F) for diesel engines], the gauge needle is held at the graduation on the far left end of the gauge scale. The gauge needle remains at the low end of the gauge scale until the cluster receives a message from the PCM or ECM indicating the temperature is above about 54° C (130° F) for gasoline engines, or about 60° C (140° F) for diesel engines, or until the ignition switch is turned to the OFF position, whichever occurs first. - Engine Temperature High Message - Each time the cluster receives three consecutive electronic engine temperature messages from the PCM or ECM indicating the temperature is above about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, the gauge needle is moved to the red increment or zone at the far right end of gauge scale, the check gauges indicator is illuminated, and a single chime tone is sounded. The gauge needle remains at the high end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the temperature is below about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the check gauges indicator is cycled OFF and then ON again by the appropriate messages from the PCM or ECM. - Communication Error - If the cluster fails to receive an engine temperature message, it will hold the gauge needle at the last indication for about 10 seconds or until the ignition switch is turned to the OFF position, whichever occurs first. After 10 seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the engine coolant temperature gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM (gasoline engine) or ECM (diesel engine) continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM or ECM then sends the proper messages to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the engine coolant temperature gauge or the instrument cluster circuitry that controls the gauge refer to Instrument Cluster/Carrier Testing. If the instrument cluster turns ON the check gauges indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. For proper diagnosis of the engine coolant temperature sensor, the PCM, the ECM, the EMIC, the CAN data bus or the electronic communication related to engine coolant temperature gauge operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications The thermostat will begin to open at 85.5 - 89.4°C (186 - 193°F). If the valve starts to move before this temperature is reached, it is opening too early. Replace thermostat. The thermostat should be fully open (valve will stop moving) at 97°C (207°F). If the valve is still moving when the water temperature reaches 97°C (207°F), it is opening too late. Replace thermostat. If the valve refuses to move at any time, replace thermostat. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 3612 Thermostat: Description and Operation DIESEL CAUTION: Do not operate an engine without a thermostat, except for servicing or testing. An engine with the thermostat removed will operate in the radiator bypass mode, causing an overheat condition. The thermostat of the diesel engine is located in the front of the cylinder head, underneath a heat shield near the thermostat housing. NOTE: The thermostat for 5.9L engine and the 6.7L are different and are not interchangeable. Use caution when replacing the thermostat to ensure the proper part number is reinstalled. An engine should not be operated without a thermostat, except for servicing or testing. Operating without a thermostat will cause overheating. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Testing and Inspection > On-Board Diagnostics Thermostat: Testing and Inspection On-Board Diagnostics ON-BOARD DIAGNOSTICS All models are equipped with On-Board Diagnostics for certain cooling system components. Refer to On-Board Diagnostics (OBD). If the powertrain control module (PCM) detects low engine coolant temperature, it will record a Diagnostic Trouble Code (DTC) in the PCM memory. Do not change a thermostat for lack of heat as indicated by the instrument panel gauge or by poor heater performance unless a DTC is present. The DTC can also be accessed through the scan tool. Refer to the appropriate Powertrain Diagnostic Procedures information for diagnostic information and operation of the scan tool. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Testing and Inspection > On-Board Diagnostics > Page 3615 Thermostat: Testing and Inspection Diesel Engine DIESEL ENGINE The cooling system used with the diesel engine provides the extra coolant capacity and extra cooling protection needed for higher GVWR (Gross Vehicle Weight Rating) and GCWR (Gross Combined Weight Rating) vehicles. This system capacity will not affect warm up or cold weather operating characteristics if the thermostat is operating properly. This is because coolant will be held in the engine until it reaches the thermostat "set" temperature. Diesel engines, due to their inherent efficiency are slower to warm up than gasoline powered engines, and will operate at lower temperatures when the vehicle is unloaded. Because of this, lower temperature gauge readings for diesel versus gasoline engines may, at times be normal. Typically, complaints of low engine coolant temperature are observed as low heater output when combined with cool or cold outside temperatures. To help promote faster engine warm-up, the electric engine block heater must be used with cool or cold outside temperatures. This will help keep the engine coolant warm when the vehicle is parked. A "Cold Weather Cover" is available from the parts department through the Mopar Accessories product line. This accessory cover is designed to block airflow entering the radiator and engine compartment to promote faster engine warm-up. It attaches to the front of the vehicle at the grill opening. The cover is to be used with cool or cold temperatures only. If used with high outside temperatures, serious engine damage could result. Refer to the literature supplied with the cover for additional information. For engines equipped with exhaust brakes, this device can be used to aid engine warm-up while the engine is idling. 1. To determine if the thermostat is defective, it must be removed from the vehicle. 2. After the thermostat has been removed, examine the thermostat and inside of thermostat housing for contaminants. If contaminants are found, the thermostat may already be in a "stuck open" position. Flush the cooling system before replacing thermostat. 3. Place the thermostat into a container filled with water. 4. Place the container on a hot plate or other suitable heating device. 5. Place a commercially available radiator thermometer into the water. 6. Apply heat to the water while observing the thermostat and thermometer. 7. The thermostat will begin to open at 85.5 - 89.4°C (186 - 193°F). If the valve starts to move before this temperature is reached, it is opening too early. Replace thermostat. The thermostat should be fully open (valve will stop moving) at 97°C (207°F). If the valve is still moving when the water temperature reaches 97°C (207°F), it is opening too late. Replace thermostat. If the valve refuses to move at any time, replace thermostat. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Removal Thermostat: Service and Repair Removal 6.7L DIESEL ENGINE WARNING: Do not loosen the radiator draincock with the system hot and pressurized. Serious burns from the coolant can occur. 1. Disconnect the battery negative cables. 2. Drain cooling system until coolant level is below thermostat. 3. Disconnect exhaust gas pressure sensor electrical connector (3). 4. Remove exhaust pressure tube (4) from thermostat housing. 5. Remove EGR cooler cross over tube (1). 6. Remove radiator hose clamp and hose from thermostat housing (1). 7. Remove heat shield. 8. Remove the three water outlet-to-cylinder head bolts (5) and remove the water outlet connector. 9. Clean the mating surfaces of the thermostat housing (1) and clean the thermostat seat groove at the top of the thermostat housing (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Removal > Page 3618 Thermostat: Service and Repair Installation 6.7L DIESEL ENGINE NOTE: The thermostat for 5.9L engine and the 6.7L are different and are not interchangeable. Use caution when replacing the thermostat to ensure the proper part number is reinstalled. 1. Inspect thermostat seal for cuts or nicks. Replace if damaged. 2. Install the thermostat into the groove in the top of the cylinder head. 3. Install the thermostat housing and bolts (5). Tighten the bolts to 10 Nm (89 in. lbs.). 4. Install heat shield. Tighten bolts to 9 Nm (79 in. lbs.). 5. Install exhaust pressure tube (4). Tighten to 10 Nm (88 in. lbs.). 6. Connect exhaust pressure sensor electrical connector (2). 7. Install EGR cross over tube (1). 8. Install P-clip and bolt. Tighten to 8 Nm (70 in. lbs.). 9. Install the radiator upper hose and clamp. 10. Fill the cooling system with coolant. 11. Connect the battery negative cables. 12. Start the engine and check for coolant leaks. Run engine to check for proper thermostat operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Install water pump with the weep hole facing downward. Tighten mounting bolts to ............................................................................. 24 Nm (18 ft. lbs.) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Description and Operation > Water Pump Water Pump: Description and Operation Water Pump Description WATER PUMP A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core. The pump is driven from the engine crankshaft by a single serpentine drive belt. The water pump impeller is pressed onto the rear of a shaft that rotates in bearings pressed into the housing. The housing has two small holes to allow seepage to escape. The water pump seals are lubricated by the antifreeze in the coolant mixture. No additional lubrication is necessary. Operation WATER PUMP A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core, this coolant absorbs the heat generated when the engine is running. The pump is driven by the engine crankshaft via a drive belt. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Description and Operation > Water Pump > Page 3624 Water Pump: Description and Operation Water Pump Bypass Description WATER PUMP BYPASS The 3.7L and 4.7L engine uses an internal water/coolant bypass system. The design uses galleries in the timing chain cover to circulate coolant during engine warm-up preventing the coolant from flowing through the radiator. Operation - 3.7L/4.7L WATER PUMP BYPASS - 3.7L/4.7L When the thermostat is in the closed position the bypass gallery is not obstructed allowing 100% flow. When the thermostat is in the open position the pill partially covers the bypass hole, reducing the amount of bypass flow. This design allows the coolant to reach operating temperature quickly when cold, while adding extra cooling during normal temperature operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Description and Operation > Page 3625 Water Pump: Testing and Inspection WATER PUMP A quick test to determine if pump is working is to check if heater warms properly. A defective water pump will not be able to circulate heated coolant through the long heater hose to the heater core. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures Water Pump: Procedures Cleaning CLEANING Clean the gasket mating surface. Use caution not to damage the gasket sealing surface. Inspection INSPECTION Inspect the water pump assembly for cracks in the housing, water leaks from shaft seal, worn bearing or impeller rubbing either the pump body or timing chain case/cover. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 3628 Water Pump: Removal and Replacement Removal 5.9L/6.7L DIESEL 1. Disconnect battery negative cables. 2. Drain cooling system. 3. Disconnect ambient air temp sensor electrical connector and mass airflow sensor electrical connector (if equipped). 4. Remove turbocharger inlet tube and air filter housing. 5. Remove generator assembly. 6. Remove the accessory drive belt. 7. Remove water pump mounting bolts (3). 8. Remove O-ring from water pump. 9. Clean water pump sealing surface on cylinder block. Installation 5.9L/6.7L DIESEL 1. Install new O-ring seal in groove on water pump. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 3629 2. Install water pump with the weep hole facing downward. Tighten mounting bolts to 24 Nm (18 ft. lbs.) torque. 3. Install generator assembly. 4. Install accessory drive belt. 5. Install air box and tube assembly. 6. Install air filter housing. 7. Fill cooling system. 8. Connect both battery cables. 9. Start and warm the engine. Check for leaks. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3636 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3637 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3638 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3639 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3640 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3641 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3642 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3643 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3646 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3647 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3648 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3649 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3650 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3651 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3652 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3653 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 3656 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 3659 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Description and Operation Exhaust Pressure Differential Sensor: Description and Operation DESCRIPTION The Exhaust Differential Pressure Sensor is remotely mounted on the transmission housing. Two pressure tubes measure pressure before and after the Diesel Particulate Filter (DPF)/Diesel Oxidation Catalyst (DOC). The sensor is critical for fail-safe of regeneration strategy, because it interprets high pressure drops as possible high soot loads. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Differential Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect electrical connector. 3. Disconnect hoses at pressure differential pressure sensor. 4. Remove mounting bolt and differential pressure sensor. 5. Remove mounting bolts (1). 6. Remove pressure differential pressure tubing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal > Page 3666 Exhaust Pressure Differential Sensor: Service and Repair Installation INSTALLATION 1. Install differential pressure tubing, if removed. Tighten fittings to 30 Nm (22 ft. lbs.). 2. Position differential pressure sensor (1). 3. Install mounting nuts (5) and bolts. Tighten to 10 Nm (89 in. lbs.). 4. Install hose (2) to the rear DPF tubing. 5. Install hose (3) to the front DPF tubing. 6. Connect electrical connector (6). 7. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > Customer Interest for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F Diesel Particle Filter (DPF): Customer Interest Engine Controls - MIL ON/DTC's P1451/P200C/P242F NUMBER: 11-001-09 GROUP: Exhaust DATE: July 23, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-002-07, DATED SEPTEMBER 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED TOOL FOR THIS PROCEDURE. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE STANDALONE MODE OR StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Diesel Particulate Filter - Diagnosis and Repair of DTC's P1451, P200C, P242F or Black Smoke From Exhaust OVERVIEW: This bulletin provides revised diagnostic and repair procedures for DTC's P1451, P2OOC, P242F, black smoke from the exhaust, or a no start condition due to a nonfunctional or plugged Diesel Particulate Filter (DPF). The Mobile DeSoot procedure initiated by the service tool will soon be replaced with a new Stationary DeSoot procedure. The stationary DeSoot procedure will only work when a vehicle needs to have a DeSoot performed, such as is indicated by the presence of an active P1451. A Service Bulletin will be released when this procedure becomes available. MODELS: 2007 - 2009 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination, warning chime and an overhead Electronic Vehicle Information Center (EVIC) message regarding the aftertreatment system and/or black smoke from the exhaust and/or a no start condition. Further Investigation by the technician may reveal that the MIL illumination and/or EVIC message is due to one or more of the following Diagnostic Trouble Codes (DTC's): ^ P1451 - Diesel Particulate Filter - System Performance. ^ P242F - Diesel Particulate Filter Restriction - Ash Accumulation. ^ P200C - Diesel Particulate Filter Over Temperature - Bank 1. NOTE: While the wiTECH tool is the preferred method of testing, StarMOBILE desktop client, StarMOBILE standalone mode OR StarSCAN may also be used to perform this procedure. DIAGNOSIS: 1. Connect the Scan Tool to the Diagnostic Link Connector (DLC). 2. Turn the ignition key to the RUN position, DO NOT start the engine. 3. From the "Vehicle View" screen on the Scan Tool select: a. "All DTCs" tab. 4. Record all Diagnostic Trouble Codes (DTC's) that are present in the PCM. NOTE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > Customer Interest for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F > Page 3675 It is IMPORTANT to record (capture) all DTC's present in the PCM prior to proceeding further with this diagnosis. 5. Are DTC's P242F and/or P200C present, either active or stored, in the PCM, or does the vehicle have visible black smoke from the exhaust or a no start condition caused by a restricted exhaust? a. If YES >> then the Diesel Particulate Filter (DPF) may require replacement. Proceed to REPAIR PROCEDURE B: DPF Repair Procedure. b. If NO >> then proceed to Step # 6. 6. Is DTC P1451 ACTIVE in the PCM (but DTC's P242F and/or P200C are NOT present and there is no black smoke concern)? a. If YES >> then a Scan Tool initiated DeSoot is required for the DPF. Proceed to REPAIR PROCEDURE A: DPF DeSoot. b. If NO >> then STOP. Additional diagnosis or repair for the DPF is not needed. An inactive DTC P1451 without other symptoms does not require any repair. Confirm that the PCM has the latest updates per the relevant TSB's and include the documentation kit p/n 6804917AA (while supplies last) in the vehicle, and resolve any other concerns prior to returning the vehicle to the owner. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURES: NOTE: Detailed removal and installation procedures (and graphics), required to perform this bulletin, will not be listed individually in each Inspection and Test Section of this Repair Procedure. It will be important to refer to TechCONNECT for all detailed service procedures. REPAIR PROCEDURE A: DPF DeSoot 1. Resolve all DTC's unrelated to DeSoot. NOTE: DeSoot only addresses the amount of particulate matter (soot) in the DPF, such as indicated by an active P1451. It DOES NOT address any other issues or conditions. 2. Confirm the PCM Calibration software is at the latest revision level. If an update is required, follow the latest calibration update TSB. WARNING: Elevated exhaust temperatures during Scan Tool initiated DeSoot can cause personal injury or property damage. It is important that ALL procedures are followed. 3. Refer to TSB or Service Information available in DealerCONNECT for information to perform a Scan Tool initiated DeSoot. REPAIR PROCEDURE B: DPF Repair Procedure NOTE: The DPF repair procedure has been updated due to diagnostic and controls enhancements. 1. Does the vehicle have a no start condition WITHOUT P242F in the PCM? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > Customer Interest for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F > Page 3676 a. If YES »> then proceed to Step # 2. b. If NO »> then proceed to Step # 3. 2. Disconnect the DPF from the NOx Absorber Catalyst (NAG) by removing the three nuts at the flange between them. Insert a non-flammable spacer between the NAG and DPF flanges to create an exhaust leak path. Does this resolve the no start condition? a. Yes >> proceed to Step # 3. b. No >> then STOP. The no start condition is NOT caused by the DPF. DPF replacement is NOT needed, and this bulletin DOES NOT apply. 3. Replace the DPF. Refer to the detailed removal and installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 11 - Exhaust Systems > Converter, Catalytic > Removal/Installation > 6.7L diesel P/U. 4. Clean the EGR valve. Refer to the detailed cleaning procedures available in DealerCONNECT > TechCONNECT under: 25 - Emissions Controls > Exhaust Gas Recirculation, 6.7L Diesel > Valve, Exhaust Gas Recirculation (EGR), 6.7L > Cleaning. 5. Ensure all other engine driveability symptom and/or aftertreatment-related DTC's are addressed. 6. Confirm the PCM application software is at the latest revision level. If an update is required, follow the latest calibration update TSB. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Use Standard Labor Operation Times FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F Diesel Particle Filter (DPF): All Technical Service Bulletins Engine Controls - MIL ON/DTC's P1451/P200C/P242F NUMBER: 11-001-09 GROUP: Exhaust DATE: July 23, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-002-07, DATED SEPTEMBER 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED TOOL FOR THIS PROCEDURE. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE STANDALONE MODE OR StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Diesel Particulate Filter - Diagnosis and Repair of DTC's P1451, P200C, P242F or Black Smoke From Exhaust OVERVIEW: This bulletin provides revised diagnostic and repair procedures for DTC's P1451, P2OOC, P242F, black smoke from the exhaust, or a no start condition due to a nonfunctional or plugged Diesel Particulate Filter (DPF). The Mobile DeSoot procedure initiated by the service tool will soon be replaced with a new Stationary DeSoot procedure. The stationary DeSoot procedure will only work when a vehicle needs to have a DeSoot performed, such as is indicated by the presence of an active P1451. A Service Bulletin will be released when this procedure becomes available. MODELS: 2007 - 2009 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination, warning chime and an overhead Electronic Vehicle Information Center (EVIC) message regarding the aftertreatment system and/or black smoke from the exhaust and/or a no start condition. Further Investigation by the technician may reveal that the MIL illumination and/or EVIC message is due to one or more of the following Diagnostic Trouble Codes (DTC's): ^ P1451 - Diesel Particulate Filter - System Performance. ^ P242F - Diesel Particulate Filter Restriction - Ash Accumulation. ^ P200C - Diesel Particulate Filter Over Temperature - Bank 1. NOTE: While the wiTECH tool is the preferred method of testing, StarMOBILE desktop client, StarMOBILE standalone mode OR StarSCAN may also be used to perform this procedure. DIAGNOSIS: 1. Connect the Scan Tool to the Diagnostic Link Connector (DLC). 2. Turn the ignition key to the RUN position, DO NOT start the engine. 3. From the "Vehicle View" screen on the Scan Tool select: a. "All DTCs" tab. 4. Record all Diagnostic Trouble Codes (DTC's) that are present in the PCM. NOTE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F > Page 3682 It is IMPORTANT to record (capture) all DTC's present in the PCM prior to proceeding further with this diagnosis. 5. Are DTC's P242F and/or P200C present, either active or stored, in the PCM, or does the vehicle have visible black smoke from the exhaust or a no start condition caused by a restricted exhaust? a. If YES >> then the Diesel Particulate Filter (DPF) may require replacement. Proceed to REPAIR PROCEDURE B: DPF Repair Procedure. b. If NO >> then proceed to Step # 6. 6. Is DTC P1451 ACTIVE in the PCM (but DTC's P242F and/or P200C are NOT present and there is no black smoke concern)? a. If YES >> then a Scan Tool initiated DeSoot is required for the DPF. Proceed to REPAIR PROCEDURE A: DPF DeSoot. b. If NO >> then STOP. Additional diagnosis or repair for the DPF is not needed. An inactive DTC P1451 without other symptoms does not require any repair. Confirm that the PCM has the latest updates per the relevant TSB's and include the documentation kit p/n 6804917AA (while supplies last) in the vehicle, and resolve any other concerns prior to returning the vehicle to the owner. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURES: NOTE: Detailed removal and installation procedures (and graphics), required to perform this bulletin, will not be listed individually in each Inspection and Test Section of this Repair Procedure. It will be important to refer to TechCONNECT for all detailed service procedures. REPAIR PROCEDURE A: DPF DeSoot 1. Resolve all DTC's unrelated to DeSoot. NOTE: DeSoot only addresses the amount of particulate matter (soot) in the DPF, such as indicated by an active P1451. It DOES NOT address any other issues or conditions. 2. Confirm the PCM Calibration software is at the latest revision level. If an update is required, follow the latest calibration update TSB. WARNING: Elevated exhaust temperatures during Scan Tool initiated DeSoot can cause personal injury or property damage. It is important that ALL procedures are followed. 3. Refer to TSB or Service Information available in DealerCONNECT for information to perform a Scan Tool initiated DeSoot. REPAIR PROCEDURE B: DPF Repair Procedure NOTE: The DPF repair procedure has been updated due to diagnostic and controls enhancements. 1. Does the vehicle have a no start condition WITHOUT P242F in the PCM? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F > Page 3683 a. If YES »> then proceed to Step # 2. b. If NO »> then proceed to Step # 3. 2. Disconnect the DPF from the NOx Absorber Catalyst (NAG) by removing the three nuts at the flange between them. Insert a non-flammable spacer between the NAG and DPF flanges to create an exhaust leak path. Does this resolve the no start condition? a. Yes >> proceed to Step # 3. b. No >> then STOP. The no start condition is NOT caused by the DPF. DPF replacement is NOT needed, and this bulletin DOES NOT apply. 3. Replace the DPF. Refer to the detailed removal and installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 11 - Exhaust Systems > Converter, Catalytic > Removal/Installation > 6.7L diesel P/U. 4. Clean the EGR valve. Refer to the detailed cleaning procedures available in DealerCONNECT > TechCONNECT under: 25 - Emissions Controls > Exhaust Gas Recirculation, 6.7L Diesel > Valve, Exhaust Gas Recirculation (EGR), 6.7L > Cleaning. 5. Ensure all other engine driveability symptom and/or aftertreatment-related DTC's are addressed. 6. Confirm the PCM application software is at the latest revision level. If an update is required, follow the latest calibration update TSB. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Use Standard Labor Operation Times FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Description and Operation > Description Diesel Particle Filter (DPF): Description and Operation Description DESCRIPTION DIESEL OXIDATION CATALYST (DOC) The diesel oxidation catalyst (DOC) is a ceramic flow through substrate coated with a catalyst washcoat that is integral to the DOC/Diesel Particulate Filter (DPF) assembly. The close coupled DOC treats engine exhaust gases by converting harmful carbon monoxide, unburned hydrocarbons and other compounds into water, carbon dioxide and heat. DIESEL PARTICULATE FILTER The diesel particulate filter (DPF) is a wall-pass ceramic filter substrate coated with a catalyst washcoat that is integral to the DOC/DPF assembly. The partially treated exhaust gases from the DOC, flow into the catalyzed diesel particulate filter (DPF) which traps and accumulates particulate matter and further treats the exhaust gases to reduce unburned hydrocarbons and other harmful compounds. the trapped particulate molecules will be periodically removed from the DPF via a thermal regeneration process initiated by the engine's electronic control module (ECM). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Description and Operation > Description > Page 3686 Diesel Particle Filter (DPF): Description and Operation Operation OPERATION The oxidation catalyst raises the exhaust gas temperatures to regenerate the DPF, which is passive regeneration. If the passive regeneration cannot keep up with the build up of soot in the DPF, the ECM will actively regenerate the DPF to burn off the soot. Residue remains inside the DPF in the form of non burnable ash. Ash comes from the oils and other materials that are trapped in the oils and are present in the soot. The catalyst contains a large number of parallel channels, which run in the axial direction and are separated by thin porous walls. The channels are alternatively open at one end, but plugged at the other. The exhaust gases flow through the walls and escape through the pores in the wall material. Particulates, however, are too large to escape and are trapped in the monolith walls. The ECM starts the regeneration of the DPF if the soot load exceeds a performance map value. The ECM determines the load condition of the DPF based upon the exhaust gas pressure upstream and downstream of the DPC/DPF. A pressure differential sensor provides the pressure input to the ECM. During the regeneration process, the ECM raises the temperature in the DOC/DPF to burn off the soot accumulated. Under normal operation, the engine does not produce enough heat to oxidize the soot inside the DOC/DPF. This process requires temperatures above 550°C (1,022°F). After regeneration, the ECM reads the actual pressure difference at the DOC/DPF and compares it with a reference value. From this comparison, the ECM determines the ash quantity inside the DOC/DPF. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Description and Operation > Page 3687 Diesel Particle Filter (DPF): Testing and Inspection DIAGNOSIS AND TESTING - DIESEL PARTICULATE FILTER EVIC Message Center - Message - Catalyst Full The engine Electronic Control Module (ECM) monitors the soot load in the diesel particulate filter. Under normal operating conditions the diesel particulate filter is self-cleaning, where accumulated soot is converted to ash. Under light load operating conditions, the driver may be notified via the vehicle's Electronic Vehicle Information Center (EVIC) message center "CATALYST FULL: SEE OWNERS MAN" message will be displayed indicating that it is necessary to modify the vehicles driving routine/duty-cycle in order to allow the diesel particulate filter system to self clean. If the vehicle's EVIC message center notification is ignored, the vehicle will eventually derate the engine and set a fault, requiring service. The soot load in the diesel particulate filter is estimated by the ECM using the Exhaust Pressure Sensor values and the calculated soot output of the engine. This fault code will be triggered if the application is not operating at a duty cycle high enough to allow active regeneration of the diesel particulate filter. This fault code is an indication that the exhaust temperatures exiting the turbocharger are not high enough to allow active regeneration of the soot that is trapped in the diesel particulate filter. It may be necessary to increase the duty cycle of the application in order to prevent excessive soot accumulation and plugging of the diesel particulate filter. The ECM will set this fault if it detects that the soot level has exceeded the normal desoot trigger threshold by a sufficient amount to indicate that the driver intervention is required. There is not a MIL lamp associated with this fault code, though the driver will be notified via the EVIC message. Have owner drive vehicle at highway speeds (50/60 mph) for a minimum of 45 minutes. If the message CATALYST FULL SERVICE REQ'D. is still displayed, Refer to - ENGINE Testing. See: Engine/Testing and Inspection/Component Tests and General Diagnostics Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Removal - Cab Chassis Diesel Particle Filter (DPF): Service and Repair Removal - Cab Chassis 6.7L DIESEL - CAB-CHASSIS WARNING: If torches are used when working on the exhaust system, do not allow the flame near the fuel lines. 1. Raise and support the vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Remove flexible tubing from particulate filter pressure sensor tubing. 4. Loosen and remove particulate filter pressure sensor tubing from Diesel Oxidation Catalytic/Diesel Particulate Filter (DOC/DPF). 5. Disconnect and remove temperature sensors. 6. 4X4 Vehicles Remove transfer case skid plate. 7. 4X4 Vehicles - Remove transmission crossmember. 8. Remove exhaust pipe to DOC/DPF flange nuts (5) 9. Remove intermediate pipe to DOC/PDF clamp nuts (2). 10. Move muffler and tail pipe assembly (1) toward rear of vehicle. 11. Remove DOC/DPF (4). 12. Remove and discard flange gaskets. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Removal - Cab Chassis > Page 3690 Diesel Particle Filter (DPF): Service and Repair Removal - P/U 6.7L DIESEL - P/U 1. Raise and support the vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Loosen and remove DPF differential pressure tubes (4 and 6). 4. Disconnect and remove temperature sensor (2). 5. 4X4 Vehicles - Remove transfer case skid plate. 6. 4X4 Vehicles - Remove transmission crossmember. 7. Remove DPF to muffler clamp (5). Discard clamp. 8. Move muffler and tail pipe assembly toward rear of vehicle. 9. Remove DPF to catalytic converter flange nuts. 10. Remove DPF. Discard flange gaskets. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Removal - Cab Chassis > Page 3691 Diesel Particle Filter (DPF): Service and Repair Installation - Cab Chassis 6.7L DIESEL - CAB-CHASSIS 1. Position new exhaust flange gaskets on exhaust pipe (6) to DOC/DPF flange and DOC/DPF into intermediate pipe (1). 2. Using new gasket, position the DOC/DPF (4) onto the front exhaust pipe flange. 3. Install flange nuts (5). Hand tighten only. 4. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 5. Tighten flange nuts (5) to 54 Nm (40 ft. lbs) 6. Tighten torque clamp nuts to 52 Nm (40 ft. lbs.) 7. Install temperature sensor. Tighten to 29.8 Nm (22 ft. lbs.) 8. Install exhaust differential pressure tubing. Tighten to 30 Nm (22 ft. lbs.) 9. Install flexible exhaust differential pressure sensor tubing. 10. 4X4 Vehicles - Install transmission crossmember. 11. 4X4 Vehicles - Install transfer case skid plate. 12. Connect electrical connectors. 13. Connect negative battery cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Removal - Cab Chassis > Page 3692 Diesel Particle Filter (DPF): Service and Repair Installation - P/U 6.7L DIESEL - P/U 1. Position new exhaust flange gaskets on catalytic converter to DPF flange. 2. Install flange bolts. Hand tighten only. 3. Install muffler and tailpipe assembly 4. Install new band clamp. Hand tighten only. 5. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 6. Tighten flange nuts to 54 Nm (40 ft. lbs) 7. Tighten band clamp nuts to 52 Nm (40 ft. lbs.) 8. Install temperature sensor. Tighten to 29.8 Nm (22 ft. lbs.) 9. Install front and rear (6 and 4) exhaust differential pressure tubing. Tighten to 30 Nm (22 ft. lbs.) 10. Install flexible exhaust differential pressure sensor tubing. 11. 4X4 Vehicles - Install transmission crossmember. 12. 4X4 Vehicles - Install transfer case skid plate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Brake > Exhaust Brake Switch > Component Information > Locations Exhaust Brake Switch: Locations Component ID: 465 Component : SWITCH-EXHAUST BRAKE Connector: Name : SWITCH-EXHAUST BRAKE Color : # of pins : 6 Qualifier : (6.7L) Pin Description Circuit 1 GROUND Z933 20BK/BR 2 PANEL LAMPS DRIVER E11 20OR/DB 3 EXHAUST BRAKE SWITCH SIGNAL G905 20BR/OR 4 S/C SWITCH RETURN V937 20VT/BR 5 EXHAUST BRAKE LAMP SIGNAL G904 20VT/DG 6-- Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Brake > Exhaust Brake Switch > Component Information > Locations > Page 3697 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Brake > Exhaust Brake Switch > Component Information > Locations > Page 3698 Exhaust Brake Switch: Diagrams Component ID: 465 Component : SWITCH-EXHAUST BRAKE Connector: Name : SWITCH-EXHAUST BRAKE Color : # of pins : 6 Qualifier : (6.7L) Pin Description Circuit 1 GROUND Z933 20BK/BR 2 PANEL LAMPS DRIVER E11 20OR/DB 3 EXHAUST BRAKE SWITCH SIGNAL G905 20BR/OR 4 S/C SWITCH RETURN V937 20VT/BR 5 EXHAUST BRAKE LAMP SIGNAL G904 20VT/DG 6-- Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Brake > Exhaust Brake Switch > Component Information > Locations > Page 3699 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Starting from the center and moving in a pattern outward, torque the exhaust manifold bolts to ............................................................. 43 Nm (32 ft. lbs.) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures Exhaust Manifold: Procedures Cleaning CLEANING Clean the cylinder head and exhaust manifold sealing surfaces with a suitable scraper. Use a Scotch-Brite(TM) pad or equivalent. Inspection INSPECTION Inspect the exhaust manifold for cracks. Measure the exhaust manifold for flatness. Place a ruler over all of the exhaust ports and insert a feeler gauge between the port flange and the ruler. Maximum deviation from flat is 0.20 mm (.008 inch). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 3705 Exhaust Manifold: Removal and Replacement Removal REMOVAL 1. Disconnect the battery negative cables. 2. Drain the coolant. See: Cooling System/Service and Repair 3. Raise vehicle on hoist. 4. Remove the EGR cooler. See: Powertrain Management/Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Removal and Replacement 5. Remove the air filter housing. See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair 6. Remove the air filter inlet hose from the turbo inlet. 7. Remove the delta-P line bracket capscrew nuts and remove the delta-P line from the exhaust manifold and thermostat housing. 8. Remove the heat shield and noise panel (if equipped) from the exhaust manifold. 9. Remove the turbocharger. See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Service and Repair/Removal and Replacement 10. Remove the two (2) rear exhaust manifold capscrew lock plates. 11. Remove the Cab Heater tubing/bracket from the exhaust manifold stud. 12. Remove the exhaust manifold. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 3706 1. Clean the exhaust manifold gasket surfaces. 2. Clean the cylinder head exhaust port gasket surfaces. 3. Clean the turbo mounting flange on the exhaust manifold. 4. Clean the turbo mounting flange on the turbocharger. 5. Install the exhaust manifold to turbocharger gasket and capscrews. 6. Install the exhaust manifold gasket. NOTE:The five exhaust manifold capscrews with studs are used at the No.1 and No.2 cylinder locations for the heat shield mounting and one on the rear lower corner of the manifold for the cabin heater tube bracket. 7. Install the exhaust manifold spacers and capscrews. 8. Starting from the center and moving in a pattern outward, tighten the exhaust manifold bolts to 43 N-m (32 ft. lbs.) 9. Install the exhaust manifold capscrew lock plates. 10. Install the exhaust manifold heat shields/noise panels. Tighten the mounting nuts to 24 N-m (18 ft. lbs.). 11. Install the turbocharger. See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Service and Repair/Removal and Replacement 12. Attach the mounting tabs and start the delta-P tube to exhaust manifold and thermostat capscrews. 13. Tighten the delta-P line bracket nut to 24 N-m (18 ft. lbs.). 14. Tighten the delta-P line bracket bolt to 10 N-m (89 in. lbs.). 15. Tighten the delta-P flare nuts to 10 N-m (89 in. lbs.). 16. Install the EGR cooler. See: Powertrain Management/Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Removal and Replacement 17. Install the air filter housing. See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair 18. Fill the coolant. See: Cooling System/Service and Repair 19. Connect the battery negative cables. 20. Start the engine to check for leaks. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Pipe-Exhaust Exhaust Pipe: Service and Repair Pipe-Exhaust Removal 6.7L DIESEL 1. Raise and support the vehicle on a hoist. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Remove the exhaust pipe-to-DOC/DPF flange nuts. 4. 4X4 Vehicles - Remove transfer case skid plate. 5. 4X4 Vehicles - Remove transmission crossmember. 6. Remove the exhaust pipe-to-turbocharger clamp and discard. 7. Remove the transmission mounted exhaust pipe support. 8. Separate the exhaust pipe and extension pipe. 9. Remove exhaust pipe. Inspection INSPECTION Discard rusted clamps, broken or worn supports and attaching parts. Replace a component with original equipment parts, or equivalent. This will assure proper alignment with other parts in the system and provide acceptable exhaust noise levels. Installation 6.7L DIESEL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Pipe-Exhaust > Page 3711 1. Using a new flange gasket, position exhaust pipe on DOC/DPF flange and turbocharger flange. 2. Install flange nuts. Tighten nuts to 24 Nm (18 ft. lbs.) 3. Install a new exhaust pipe-to-turbocharger clamp. Do not tighten clamp at this time. 4. Install transmission mounted exhaust pipe support. Tighten bolts to 43 Nm (32 ft. lbs.). 5. 4X4 Vehicles - Install transmission crossmember. 6. 4X4 Vehicles - Install transfer case skid plate. 7. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 8. Tighten turbocharger clamp nut to 11 Nm (97 in. lbs.). 9. Lower the vehicle. 10. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Pipe-Exhaust > Page 3712 Exhaust Pipe: Service and Repair Tailpipe Removal DIESEL 1. Disconnect the battery negative cables. 2. Raise and support the vehicle. 3. Saturate the clamp nuts with heat valve lubricant. Allow 5 minutes for penetration. 4. Disconnect the exhaust tailpipe support hanger isolators. 5. Remove the muffler-to-tailpipe clamps. 6. Remove the tailpipe from the vehicle. Inspection INSPECTION Discard rusted clamps, broken or worn supports and attaching parts. Replace a component with original equipment parts, or equivalent. This will assure proper alignment with other parts in the system and provide acceptable exhaust noise levels. Installation DIESEL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Pipe-Exhaust > Page 3713 1. Install the tailpipe into the muffler. 2. Install the tailpipe hanger rods into the isolators 3. Install the exhaust clamp, align the exhaust system, and tighten the clamp 48 Nm (35 ft. lbs.) torque. 4. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 5. Lower the vehicle. 6. Connect the battery negative cables. 7. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3718 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3719 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3720 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3721 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3722 Component Location - 25 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3723 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3726 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3727 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3728 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3729 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3730 Component Location - 25 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3731 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation Heat Shield: Description and Operation DESCRIPTION There are two types of heat shields used. One is stamped steel the other is molded foil sheets. The shields attach to the vehicle around the exhaust system to prevent heat from the exhaust system from entering the passenger area and other areas where the heat can cause damage to other components. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Removal Heat Shield: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the nuts or bolts holding the exhaust heat shield to the floor pan, crossmember or bracket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Removal > Page 3737 3. Slide the shield out around the exhaust system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Removal > Page 3738 Heat Shield: Service and Repair Installation INSTALLATION 1. Position the exhaust heat shield to the floor pan, crossmember or bracket and install the nuts or bolts. 2. Tighten the nuts and bolts 11 Nm (100 in. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Removal > Page 3739 3. Lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Removal Muffler: Service and Repair Removal DIESEL 1. Disconnect the battery negative cables. 2. Raise and support the vehicle. 3. Remove the muffler to tail pipe and extension pipe clamps. 4. Disconnect the muffler from the hanger isolators. 5. Disconnect the muffler from the tailpipe. 6. Disconnect the muffler from the extension pipe and remove from the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Removal > Page 3744 Muffler: Service and Repair Installation DIESEL 1. Install the muffler hanger rods into the isolators. 2. Install the muffler into the extension pipe. 3. Install the muffler into the tail pipe. 4. Install the exhaust clamps, align the exhaust system, and tighten the exhaust clamps to 54 Nm (40 ft. lbs.) torque. 5. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 6. Lower the vehicle. 7. Connect the battery negative cables. 8. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3750 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3751 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3752 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3753 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3754 Component Location - 25 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3755 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3758 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3759 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3760 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3761 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3762 Component Location - 25 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3763 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3768 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3769 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3770 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3771 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3772 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3773 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3774 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3775 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3778 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3779 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3780 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3781 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3782 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3783 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3784 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3785 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 3788 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 3791 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3799 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3800 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3801 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3802 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3803 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3804 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3805 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3806 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3807 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3808 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3809 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3810 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3811 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3812 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3813 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3814 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3815 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3816 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness Technical Service Bulletin # K01 Date: 100510 Recall - ECM Update For OBD Readiness May 2010 Dealer Service Instructions for: California Emissions Recall K01 Reprogram ECM OBD Readiness Effective immediately all repairs on involved vehicles are to be performed according to this notification. Service Bulletin 18-038-09 is no longer applicable for the involved vehicles only. Models 2003 (DR) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETC) and a California emission control system (sales code NAE). 2006-2007 (DH/D1) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETH) and a California emission control system (sales code NAE). 2007 (DC) Dodge Ram Truck (3500 series cab chassis) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ) and a California emission control system (sales code NAE) built through January 5, 2007 (MDH010508). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process or GRS DealerCONNECT functions. Subject The Engine Control Module (ECM) on about 25,208 of the above vehicles may fail to accurately report diagnostic system information with some generic scan tools. This may cause the vehicle to be rejected or fail an Inspection/Maintenance Test (also known as a Smog Check). Repair The Engine Control Module (ECM) must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Part Number Description 04275086AB Authorized Modifications Label Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 3825 The special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the label plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 3826 To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: The DRBIII(R) must be used to perform this recall on 2003 Model Year (MY) vehicles. The 2003 MY procedure is found in Section D of the Service Procedure. Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall on 2006-2007 MY vehicles. This procedure must be performed with software release level 10.03 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 3827 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's" button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section E. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 3828 h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section E. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 3829 e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 10. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 9. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 10. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 11. Continue with Section E. Install Authorized Modification Label. D. Reprogram the ECM Using DRBIII(R): The DealerCONNECT System, DRBIII(R) (Diagnostic Readout Box scan tool), CH7000A flash cable and CH7035B data cable are required to perform this repair. Do not attempt to perform the flash procedure using an outdated CH7000/CH7001 flash cable. NOTE: Whenever a controller is reprogrammed, the software in the DRBIII scan tool must be programmed with the latest revision level available. NOTE: If the flash process is interrupted or aborted, the flash should be restarted and then follow the directions on the DRBIII scan tool. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 3830 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the DRBIII CH7000A flash cable from the DRBIII scan tool to the data link connector located inside the vehicle under the steering column. 3. Connect the CH7035B data cable from the DealerCONNECT machine to the MDS port on the DRBIII scan tool. 4. Place the vehicle's ignition key in the "RUN" position. 5. From the DealerCONNECT "WELCOME" screen, enter your "User I.D.," "Password" and "Dealer Code". 6. From the DealerCONNECT "HOME PAGE" select the "SERVICE" tab. 7. From the "SERVICE" tab screen select "TechTOOLS". 8. If the DRBIII scan tool does not "Auto Connect" select # 2 on the DRBIII key pad "Connect to TechCONNECT". 9. After the "Auto Connect" process is complete, select "READ PART NUMBER(S) FROM VEHICLE" on the TechCONNECT screen. 10. Continue following the TechCONNECT on-screen instructions. 11. Select the applicable update calibration. 12. Select the "DRBIII" button located at the bottom of the TechCONNECT monitor screen. 13. Select the "DOWNLOAD / UPDATE" button located next to the "DRBIII" button. NOTE: The system software will automatically download to the DRBIII scan tool. 14. After the software download to the DRBIII scan tool is complete, close the "DOWNLOAD / UPDATE PROGRESS" window. 15. Disconnect the DRBIII scan tool from the TechCONNECT CH7035B data cable. 16. Select # 1 "RETURN TO NORMAL MODE" on the DRBIII scan tool. 17. Use the following procedure to download the flash from the DRBIII scan tool to the vehicle. a. Select # 7 "VEHICLE FLASH" on the DRBIII scan tool. b. Follow the directions displayed on the DRBIII scan tool screen. c. After the reprogramming is complete, record the new module part number displayed on the DRBIII scan tool screen. d. Press the "PAGE BACK" button on the DRBIII scan tool. 18. Due to the ECM flash procedure, Diagnostic Trouble Codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS, ORC) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules, record the trouble codes, and erase the trouble codes using the following procedure: a. Turn the vehicle's ignition key to the "RUN" position. b. From the DRBIII scan tool Main Menu select # 1 "DRBIII Stand-Alone". c. From the DRBIII scan tool Stand-Alone menu select # 3 "Vehicle Module Scan". d. From the DRBIII scan tool Vehicle Module Scan menu select # 1 "1998 - 2005 Module Scan". e. Select "YES" on the DRBIII scan tool key pad to scan for DTC's. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 3831 f. Follow the instructions on the DRBIII scan tool screen. g. Once the scanning process is complete, the DRBIII scan tool will display a list of all the modules. Modules on the list that have an asterisk next to them have DTC's that need to be cleared. h. Select the module that needs to have the DTC's cleared and follow the instructions on the DRBIII scan tool screen to clear the DTC's. i. Turn the vehicle's ignition key to the "OFF" position. NOTE: Erase any DTC's in the ECM only after all other modules have had their DTC's erased. 19. Disconnect the DRBIII scan tool from the vehicle. 20. Turn off the battery charger and disconnect it from the vehicle. 21. Continue with Section E. Install Authorized Modification Label. E. Install the Authorized Modifications Label: 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 3832 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3837 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3838 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3839 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3840 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3841 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3842 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3843 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-003-10 > Sep > 10 > Engine Controls - ECM Update for Fan Clutch Operation Engine Control Module: Customer Interest Engine Controls - ECM Update for Fan Clutch Operation NUMBER: 07-003-10 GROUP: Cooling DATE: September 09, 2010 SUBJECT: High Coolant Temperatures On Vehicles Equipped With Snow Plows OVERVIEW: This bulletin provides information on how to program the Engine Control Module (ECM) to force the fan clutch to fully engage at all operating conditions MODELS: 2007 - 2010 DC/DM Ram 3500/4500/5500 Cab Chassis Trucks 2011 DD/DP Ram 3500/4500/5500 Cab Chassis Trucks NOTE: This bulletin applies to vehicles equipped with the 6.7L Cummins Diesel engine (Sales Code ETJ) DISCUSSION: Customers that operate their vehicle with a snowplow attached to the vehicle may cause the airflow passing through the radiator to be disrupted resulting in higher than normal engine temperatures The 6~7L Cummins ECM is equipped with software that can fully engage the fan clutch to allow an increase of airflow through the radiator Customers can initiate the fan clutch operation by performing the following button sequence NOTE: 2007 early 2009 models were not originally equipped with the fan clutch software however, recently released software does include this enhancement Ensure that the ECM software is at the latest level and if not, flash the ECM Refer to Service Bulletin 18-020-10 for additional information 1. Turn the ignition key to the run position or start the truck 2. Simultaneously press and release the Cruise Control "Cancel" button/lever and the "Exhaust Brake" button. Repeat this sequence four times within five seconds. The chime will sound twice as an audible indicator that the function is engaged 3. To disable the function, repeat the same procedure The chime will sound four times as an audible indicator that the function is disengaged NOTE: Customer's should be made aware that an increase in fan noise and a decrease in fuel economy may result when using this feature. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements Engine Control Module: Customer Interest Engine Controls - Engine Systems/Exhaust Enhancements NUMBER: 18-020-10 GROUP: Vehicle Performance DATE: June 10, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-06, DATED DECEMBER 05, 2006 AND 18-001-09, DATED JANUARY 21, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. Either wiTECH OR StarMOBILE DESKTOP CLIENT can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. StarMOBILE® SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. SUBJECT: FLASH: Engine Systems And Exhaust Aftertreatment Systems Enhancements OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement based on customer use and mileage accumulation. This bulletin involves: ^ Selectively erasing and reprogramming the Engine Control Module (PCM), 2007 - 2010 MY. ^ Selectively erasing and reprogramming the Cab Compartment Node (CCN), 2007 & 2008 MY. ^ If CCN is updated; provide a Customer Information Sheet explaining the overhead display messages. ^ One of several software changes allows for "Net Zero" and "Net Reduction" which will cause noticeable changes in idle speeds. Customers should be informed of these changes. They are explained in DISCUSSION, Improvements that address erroneous MIL illumination for DTC P0106, P0191, P2262 and P2299 DTC's, (spelled out in DISCUSSION below). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. MODELS: 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) 2008 - 2010 (DM) Ram Truck (4500/5500 Cab Chassis) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). NOTE: For some 2007 MY vehicles, the ECM flash is addressed in Recall K01, Dated May, 2010. Where applicable. please use the Recall to update the ECM and this bulletin to update the CCN software. DISCUSSION: Cab chassis trucks equipped with a 6.7L Cummins diesel have a number of software improvements available. This latest Service Bulletin (SB) will include improvements to prevent erroneous Malfunction Indicator Lamp (MIL) illumination: ^ P000F - Fuel System Over Pressure Relief Valve Activated Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 3853 ^ P0087 - Fuel Rail Pressure Too Low ^ P0106 - Manifold Absolute Pressure Sensor Performance ^ P0191 - Fuel Rail Pressure Sensor Circuit Performance ^ P1011 - Fuel Pump Delivery Pressure Too Low ^ P2299 - Brake Pedal Position / Accelerator Pedal Position Incompatible ^ P2262 - Turbocharger Boost Pressure Not Detected - Mechanical Other updates will include the following operational and diagnostic improvements: 1. Stationary DeSoot is now available with this software. This feature works similar to pick up truck (DH/D1) models. 2. New DTC added for P2563 - Turbocharger Boost Control Position Sensor Performance. This DTC indicates diminished variable geometry turbocharger travel, which is resolved by replacing the turbocharger. Diagnosis and repair procedures for the DTC have been published in DTC-Based Diagnostics in TechConnect. 3. The latest PCM software includes a new extended idle feature to accommodate the extended idle times present in some duty cycles. This feature may help to reduce the accumulation of soot in the exhaust aftertreatment system when the engine is idling for an extended period of time. Briefly how this feature works: a. As needed, the engine enters an idling mode which dramatically reduces the rate of soot accumulation in the diesel particulate filter (called "Net Zero"). Further, under extended idle periods of 5 minutes or longer, the engine enters a mode which reduces the amount of soot accumulated in the diesel particulate filter (called "Net Reduction"). While in these modes, the idle speed increases to 900 RPM for a period of time. The idle speed may return to normal idle speed and then return to 900 RPM to repeat this cycle during very long idle periods. b. These modes occur automatically depending on the need to regenerate the DPF as long as the vehicle is not driven over 20 MPH or operated at high load. If the vehicle is driven over 20 MPH normal mobile desoot will occur automatically. 4. New scan tool driven fuel system diagnostic tests (same as previously released in the pick up) now available for cab chassis. DIAGNOSIS: 1. Using the scan tool, determine current software level of the PCM and CCN. Record on the repair order, for later use, the current PCM and CCN software level part numbers. Proceed to the next step. 2. Compare the current PCM software level part number with software available in the scantool. Determine if the current PCM software level part number, recorded in Step # 1, is programmable to a higher level. 3. Is the part number of the current PCM level software (recorded in Step # 1) at the latest level listed in the scan tool? a. If YES >> then the PCM DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. b. If NO >> then the PCM DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. 4. Is the vehicle a 2007 OR 2008 MY? a. Yes >>> Proceed to Step # 5. b. No >>> 2009 MY proceed to the REPAIR PROCEDURE as required. 5. Determine if the current CCN module level software part number, that was recorded earlier in Step # 1, is one of the following (or with a higher suffix): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 3854 a. 05172187AH (or higher) = 2007 DC (3500). b. 05172334AG (or higher) = 2008 DC (3500) / DM (3500/4500). c. 2009 & 2010 MY vehicles came equipped with proper CCN software. 6. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 5? a. If YES >>> then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. b. If NO >>> then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. PARTS REQUIRED: REPAIR PROCEDURE; ECM MODULE REPROGRAM: NOTE: The wiTECH diagnostic application is the preferred method for flashing ECU's. Help using the wiTECH diagnostic application for flashing an ECU is available by selecting "Help" then "Help Contents" at the top of the wiTECH diagnostic application window. NOTE: The wiTECH software level must be at release 10.04 or higher to perform this procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. If required, as determined in DIAGNOSIS, above: reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > 8E - Electronic Control Modules >MODULE, Engine Control, Diesel > Service Information > Standard Procedure > PCM/ECM Programming - DIESEL. After PCM reprogramming, the following must be performed: a. Clear any DIG's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 3. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. 4. If required, as determined in DIAGNOSIS, above: reprogram the CCN using one of the following procedures, (based on scan tool use). 5. Was it determined in DIAGNOSIS, Step # 6 above, the CCN required updating? a. Yes >>> Proceed to appropriate CCN Module Reprogram Procedure Below, based on the scantool used. b. No >>> Repair is complete. NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 3855 NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. CCN MODULE REPROGRAM - USING wiTECH(R): 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id and "Password", then select "OK". 6. Select the "Next tab at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash" screen follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF position", remove the wiPOD(R) and battery charger from the vehicle. StarMOBILE(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident" flash file for statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 3856 b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step Se, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number (displayed at the end of the "Resident flash file for statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 3857 Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "Exhaust Filter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required - See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test Engine Control Module: Customer Interest Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 3862 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set Engine Control Module: Customer Interest Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 3867 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 3868 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: Customer Interest Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3873 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3874 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3875 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3876 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 07-003-10 > Sep > 10 > Engine Controls - ECM Update for Fan Clutch Operation Engine Control Module: All Technical Service Bulletins Engine Controls - ECM Update for Fan Clutch Operation NUMBER: 07-003-10 GROUP: Cooling DATE: September 09, 2010 SUBJECT: High Coolant Temperatures On Vehicles Equipped With Snow Plows OVERVIEW: This bulletin provides information on how to program the Engine Control Module (ECM) to force the fan clutch to fully engage at all operating conditions MODELS: 2007 - 2010 DC/DM Ram 3500/4500/5500 Cab Chassis Trucks 2011 DD/DP Ram 3500/4500/5500 Cab Chassis Trucks NOTE: This bulletin applies to vehicles equipped with the 6.7L Cummins Diesel engine (Sales Code ETJ) DISCUSSION: Customers that operate their vehicle with a snowplow attached to the vehicle may cause the airflow passing through the radiator to be disrupted resulting in higher than normal engine temperatures The 6~7L Cummins ECM is equipped with software that can fully engage the fan clutch to allow an increase of airflow through the radiator Customers can initiate the fan clutch operation by performing the following button sequence NOTE: 2007 early 2009 models were not originally equipped with the fan clutch software however, recently released software does include this enhancement Ensure that the ECM software is at the latest level and if not, flash the ECM Refer to Service Bulletin 18-020-10 for additional information 1. Turn the ignition key to the run position or start the truck 2. Simultaneously press and release the Cruise Control "Cancel" button/lever and the "Exhaust Brake" button. Repeat this sequence four times within five seconds. The chime will sound twice as an audible indicator that the function is engaged 3. To disable the function, repeat the same procedure The chime will sound four times as an audible indicator that the function is disengaged NOTE: Customer's should be made aware that an increase in fan noise and a decrease in fuel economy may result when using this feature. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Systems/Exhaust Enhancements NUMBER: 18-020-10 GROUP: Vehicle Performance DATE: June 10, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-06, DATED DECEMBER 05, 2006 AND 18-001-09, DATED JANUARY 21, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. Either wiTECH OR StarMOBILE DESKTOP CLIENT can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. StarMOBILE® SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. SUBJECT: FLASH: Engine Systems And Exhaust Aftertreatment Systems Enhancements OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement based on customer use and mileage accumulation. This bulletin involves: ^ Selectively erasing and reprogramming the Engine Control Module (PCM), 2007 - 2010 MY. ^ Selectively erasing and reprogramming the Cab Compartment Node (CCN), 2007 & 2008 MY. ^ If CCN is updated; provide a Customer Information Sheet explaining the overhead display messages. ^ One of several software changes allows for "Net Zero" and "Net Reduction" which will cause noticeable changes in idle speeds. Customers should be informed of these changes. They are explained in DISCUSSION, Improvements that address erroneous MIL illumination for DTC P0106, P0191, P2262 and P2299 DTC's, (spelled out in DISCUSSION below). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. MODELS: 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) 2008 - 2010 (DM) Ram Truck (4500/5500 Cab Chassis) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). NOTE: For some 2007 MY vehicles, the ECM flash is addressed in Recall K01, Dated May, 2010. Where applicable. please use the Recall to update the ECM and this bulletin to update the CCN software. DISCUSSION: Cab chassis trucks equipped with a 6.7L Cummins diesel have a number of software improvements available. This latest Service Bulletin (SB) will include improvements to prevent erroneous Malfunction Indicator Lamp (MIL) illumination: ^ P000F - Fuel System Over Pressure Relief Valve Activated Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 3886 ^ P0087 - Fuel Rail Pressure Too Low ^ P0106 - Manifold Absolute Pressure Sensor Performance ^ P0191 - Fuel Rail Pressure Sensor Circuit Performance ^ P1011 - Fuel Pump Delivery Pressure Too Low ^ P2299 - Brake Pedal Position / Accelerator Pedal Position Incompatible ^ P2262 - Turbocharger Boost Pressure Not Detected - Mechanical Other updates will include the following operational and diagnostic improvements: 1. Stationary DeSoot is now available with this software. This feature works similar to pick up truck (DH/D1) models. 2. New DTC added for P2563 - Turbocharger Boost Control Position Sensor Performance. This DTC indicates diminished variable geometry turbocharger travel, which is resolved by replacing the turbocharger. Diagnosis and repair procedures for the DTC have been published in DTC-Based Diagnostics in TechConnect. 3. The latest PCM software includes a new extended idle feature to accommodate the extended idle times present in some duty cycles. This feature may help to reduce the accumulation of soot in the exhaust aftertreatment system when the engine is idling for an extended period of time. Briefly how this feature works: a. As needed, the engine enters an idling mode which dramatically reduces the rate of soot accumulation in the diesel particulate filter (called "Net Zero"). Further, under extended idle periods of 5 minutes or longer, the engine enters a mode which reduces the amount of soot accumulated in the diesel particulate filter (called "Net Reduction"). While in these modes, the idle speed increases to 900 RPM for a period of time. The idle speed may return to normal idle speed and then return to 900 RPM to repeat this cycle during very long idle periods. b. These modes occur automatically depending on the need to regenerate the DPF as long as the vehicle is not driven over 20 MPH or operated at high load. If the vehicle is driven over 20 MPH normal mobile desoot will occur automatically. 4. New scan tool driven fuel system diagnostic tests (same as previously released in the pick up) now available for cab chassis. DIAGNOSIS: 1. Using the scan tool, determine current software level of the PCM and CCN. Record on the repair order, for later use, the current PCM and CCN software level part numbers. Proceed to the next step. 2. Compare the current PCM software level part number with software available in the scantool. Determine if the current PCM software level part number, recorded in Step # 1, is programmable to a higher level. 3. Is the part number of the current PCM level software (recorded in Step # 1) at the latest level listed in the scan tool? a. If YES >> then the PCM DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. b. If NO >> then the PCM DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. 4. Is the vehicle a 2007 OR 2008 MY? a. Yes >>> Proceed to Step # 5. b. No >>> 2009 MY proceed to the REPAIR PROCEDURE as required. 5. Determine if the current CCN module level software part number, that was recorded earlier in Step # 1, is one of the following (or with a higher suffix): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 3887 a. 05172187AH (or higher) = 2007 DC (3500). b. 05172334AG (or higher) = 2008 DC (3500) / DM (3500/4500). c. 2009 & 2010 MY vehicles came equipped with proper CCN software. 6. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 5? a. If YES >>> then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. b. If NO >>> then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. PARTS REQUIRED: REPAIR PROCEDURE; ECM MODULE REPROGRAM: NOTE: The wiTECH diagnostic application is the preferred method for flashing ECU's. Help using the wiTECH diagnostic application for flashing an ECU is available by selecting "Help" then "Help Contents" at the top of the wiTECH diagnostic application window. NOTE: The wiTECH software level must be at release 10.04 or higher to perform this procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. If required, as determined in DIAGNOSIS, above: reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > 8E - Electronic Control Modules >MODULE, Engine Control, Diesel > Service Information > Standard Procedure > PCM/ECM Programming - DIESEL. After PCM reprogramming, the following must be performed: a. Clear any DIG's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 3. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. 4. If required, as determined in DIAGNOSIS, above: reprogram the CCN using one of the following procedures, (based on scan tool use). 5. Was it determined in DIAGNOSIS, Step # 6 above, the CCN required updating? a. Yes >>> Proceed to appropriate CCN Module Reprogram Procedure Below, based on the scantool used. b. No >>> Repair is complete. NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 3888 NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. CCN MODULE REPROGRAM - USING wiTECH(R): 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id and "Password", then select "OK". 6. Select the "Next tab at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash" screen follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF position", remove the wiPOD(R) and battery charger from the vehicle. StarMOBILE(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident" flash file for statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 3889 b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step Se, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number (displayed at the end of the "Resident flash file for statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 3890 Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "Exhaust Filter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required - See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test Engine Control Module: All Technical Service Bulletins Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 3895 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 3900 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 3901 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness Technical Service Bulletin # K01 Date: 100510 Recall - ECM Update For OBD Readiness May 2010 Dealer Service Instructions for: California Emissions Recall K01 Reprogram ECM OBD Readiness Effective immediately all repairs on involved vehicles are to be performed according to this notification. Service Bulletin 18-038-09 is no longer applicable for the involved vehicles only. Models 2003 (DR) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETC) and a California emission control system (sales code NAE). 2006-2007 (DH/D1) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETH) and a California emission control system (sales code NAE). 2007 (DC) Dodge Ram Truck (3500 series cab chassis) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ) and a California emission control system (sales code NAE) built through January 5, 2007 (MDH010508). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process or GRS DealerCONNECT functions. Subject The Engine Control Module (ECM) on about 25,208 of the above vehicles may fail to accurately report diagnostic system information with some generic scan tools. This may cause the vehicle to be rejected or fail an Inspection/Maintenance Test (also known as a Smog Check). Repair The Engine Control Module (ECM) must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Part Number Description 04275086AB Authorized Modifications Label Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 3906 The special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the label plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 3907 To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: The DRBIII(R) must be used to perform this recall on 2003 Model Year (MY) vehicles. The 2003 MY procedure is found in Section D of the Service Procedure. Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall on 2006-2007 MY vehicles. This procedure must be performed with software release level 10.03 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 3908 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's" button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section E. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 3909 h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section E. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 3910 e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 10. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 9. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 10. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 11. Continue with Section E. Install Authorized Modification Label. D. Reprogram the ECM Using DRBIII(R): The DealerCONNECT System, DRBIII(R) (Diagnostic Readout Box scan tool), CH7000A flash cable and CH7035B data cable are required to perform this repair. Do not attempt to perform the flash procedure using an outdated CH7000/CH7001 flash cable. NOTE: Whenever a controller is reprogrammed, the software in the DRBIII scan tool must be programmed with the latest revision level available. NOTE: If the flash process is interrupted or aborted, the flash should be restarted and then follow the directions on the DRBIII scan tool. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 3911 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the DRBIII CH7000A flash cable from the DRBIII scan tool to the data link connector located inside the vehicle under the steering column. 3. Connect the CH7035B data cable from the DealerCONNECT machine to the MDS port on the DRBIII scan tool. 4. Place the vehicle's ignition key in the "RUN" position. 5. From the DealerCONNECT "WELCOME" screen, enter your "User I.D.," "Password" and "Dealer Code". 6. From the DealerCONNECT "HOME PAGE" select the "SERVICE" tab. 7. From the "SERVICE" tab screen select "TechTOOLS". 8. If the DRBIII scan tool does not "Auto Connect" select # 2 on the DRBIII key pad "Connect to TechCONNECT". 9. After the "Auto Connect" process is complete, select "READ PART NUMBER(S) FROM VEHICLE" on the TechCONNECT screen. 10. Continue following the TechCONNECT on-screen instructions. 11. Select the applicable update calibration. 12. Select the "DRBIII" button located at the bottom of the TechCONNECT monitor screen. 13. Select the "DOWNLOAD / UPDATE" button located next to the "DRBIII" button. NOTE: The system software will automatically download to the DRBIII scan tool. 14. After the software download to the DRBIII scan tool is complete, close the "DOWNLOAD / UPDATE PROGRESS" window. 15. Disconnect the DRBIII scan tool from the TechCONNECT CH7035B data cable. 16. Select # 1 "RETURN TO NORMAL MODE" on the DRBIII scan tool. 17. Use the following procedure to download the flash from the DRBIII scan tool to the vehicle. a. Select # 7 "VEHICLE FLASH" on the DRBIII scan tool. b. Follow the directions displayed on the DRBIII scan tool screen. c. After the reprogramming is complete, record the new module part number displayed on the DRBIII scan tool screen. d. Press the "PAGE BACK" button on the DRBIII scan tool. 18. Due to the ECM flash procedure, Diagnostic Trouble Codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS, ORC) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules, record the trouble codes, and erase the trouble codes using the following procedure: a. Turn the vehicle's ignition key to the "RUN" position. b. From the DRBIII scan tool Main Menu select # 1 "DRBIII Stand-Alone". c. From the DRBIII scan tool Stand-Alone menu select # 3 "Vehicle Module Scan". d. From the DRBIII scan tool Vehicle Module Scan menu select # 1 "1998 - 2005 Module Scan". e. Select "YES" on the DRBIII scan tool key pad to scan for DTC's. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 3912 f. Follow the instructions on the DRBIII scan tool screen. g. Once the scanning process is complete, the DRBIII scan tool will display a list of all the modules. Modules on the list that have an asterisk next to them have DTC's that need to be cleared. h. Select the module that needs to have the DTC's cleared and follow the instructions on the DRBIII scan tool screen to clear the DTC's. i. Turn the vehicle's ignition key to the "OFF" position. NOTE: Erase any DTC's in the ECM only after all other modules have had their DTC's erased. 19. Disconnect the DRBIII scan tool from the vehicle. 20. Turn off the battery charger and disconnect it from the vehicle. 21. Continue with Section E. Install Authorized Modification Label. E. Install the Authorized Modifications Label: 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 3913 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3918 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3919 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3920 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3921 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3926 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3927 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3928 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3929 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3930 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3931 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3932 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-030-07 > Apr > 07 > Engine Controls - Engine Off Idle Speed Limit Feature Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Off Idle Speed Limit Feature NUMBER: 18-030-07 GROUP: Vehicle Performance DATE: April 26, 2007 SUBJECT: Engine Off-Idle Speed Limit Feature To Protect Turbocharger When Vehicle Is Not Moving OVERVIEW: This bulletin involves a discussion regarding an engine control feature that limits engine off-idle speeds when the vehicle is not moving. MODELS: 2004 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 5.9L or a 6.7L Cummins turbo-diesel engine (sale codes: ETC, ETH, or ETJ). DISCUSSION: Dependent upon engine coolant temperature, the Engine Control Module (ECM) will temporarily delay (limit) the maximum engine speed when the vehicle is not moving. For automatic transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph, and when the transmission selector is in either the neutral or park position. For manual transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph. This ECM feature is used to protect the engine turbocharger. By temporarily limiting the vehicle engine speed, the shaft speed of the engine turbocharger is controlled to a low speed. This delay in maximum engine and turbo-charger shaft speed allows for sufficient oil lubrication to the turbocharger shaft bearings. Satisfactory oil lubrication of the turbocharger shaft bearings is important for long term turbocharger durability. The maximum engine speed for the 5.9L engine is temporarily limited to 1,600 RPM's when the above conditions are met. The 6.7L engine speed is temporarily limited to 1,200 RPM's when the above conditions are met. The length of time that the maximum engine speed is temporarily limited is dependent upon engine coolant temperature. Refer to the table to determine the amount of Time Delay. NOTE: The time delay values supplied in the table are an approximation and may vary per application. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Engine Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 3941 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 3942 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 3943 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 07-003-10 > Sep > 10 > Engine Controls - ECM Update for Fan Clutch Operation Engine Control Module: All Technical Service Bulletins Engine Controls - ECM Update for Fan Clutch Operation NUMBER: 07-003-10 GROUP: Cooling DATE: September 09, 2010 SUBJECT: High Coolant Temperatures On Vehicles Equipped With Snow Plows OVERVIEW: This bulletin provides information on how to program the Engine Control Module (ECM) to force the fan clutch to fully engage at all operating conditions MODELS: 2007 - 2010 DC/DM Ram 3500/4500/5500 Cab Chassis Trucks 2011 DD/DP Ram 3500/4500/5500 Cab Chassis Trucks NOTE: This bulletin applies to vehicles equipped with the 6.7L Cummins Diesel engine (Sales Code ETJ) DISCUSSION: Customers that operate their vehicle with a snowplow attached to the vehicle may cause the airflow passing through the radiator to be disrupted resulting in higher than normal engine temperatures The 6~7L Cummins ECM is equipped with software that can fully engage the fan clutch to allow an increase of airflow through the radiator Customers can initiate the fan clutch operation by performing the following button sequence NOTE: 2007 early 2009 models were not originally equipped with the fan clutch software however, recently released software does include this enhancement Ensure that the ECM software is at the latest level and if not, flash the ECM Refer to Service Bulletin 18-020-10 for additional information 1. Turn the ignition key to the run position or start the truck 2. Simultaneously press and release the Cruise Control "Cancel" button/lever and the "Exhaust Brake" button. Repeat this sequence four times within five seconds. The chime will sound twice as an audible indicator that the function is engaged 3. To disable the function, repeat the same procedure The chime will sound four times as an audible indicator that the function is disengaged NOTE: Customer's should be made aware that an increase in fan noise and a decrease in fuel economy may result when using this feature. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Systems/Exhaust Enhancements NUMBER: 18-020-10 GROUP: Vehicle Performance DATE: June 10, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-06, DATED DECEMBER 05, 2006 AND 18-001-09, DATED JANUARY 21, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. Either wiTECH OR StarMOBILE DESKTOP CLIENT can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. StarMOBILE® SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. SUBJECT: FLASH: Engine Systems And Exhaust Aftertreatment Systems Enhancements OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement based on customer use and mileage accumulation. This bulletin involves: ^ Selectively erasing and reprogramming the Engine Control Module (PCM), 2007 - 2010 MY. ^ Selectively erasing and reprogramming the Cab Compartment Node (CCN), 2007 & 2008 MY. ^ If CCN is updated; provide a Customer Information Sheet explaining the overhead display messages. ^ One of several software changes allows for "Net Zero" and "Net Reduction" which will cause noticeable changes in idle speeds. Customers should be informed of these changes. They are explained in DISCUSSION, Improvements that address erroneous MIL illumination for DTC P0106, P0191, P2262 and P2299 DTC's, (spelled out in DISCUSSION below). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. MODELS: 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) 2008 - 2010 (DM) Ram Truck (4500/5500 Cab Chassis) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). NOTE: For some 2007 MY vehicles, the ECM flash is addressed in Recall K01, Dated May, 2010. Where applicable. please use the Recall to update the ECM and this bulletin to update the CCN software. DISCUSSION: Cab chassis trucks equipped with a 6.7L Cummins diesel have a number of software improvements available. This latest Service Bulletin (SB) will include improvements to prevent erroneous Malfunction Indicator Lamp (MIL) illumination: ^ P000F - Fuel System Over Pressure Relief Valve Activated Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 3953 ^ P0087 - Fuel Rail Pressure Too Low ^ P0106 - Manifold Absolute Pressure Sensor Performance ^ P0191 - Fuel Rail Pressure Sensor Circuit Performance ^ P1011 - Fuel Pump Delivery Pressure Too Low ^ P2299 - Brake Pedal Position / Accelerator Pedal Position Incompatible ^ P2262 - Turbocharger Boost Pressure Not Detected - Mechanical Other updates will include the following operational and diagnostic improvements: 1. Stationary DeSoot is now available with this software. This feature works similar to pick up truck (DH/D1) models. 2. New DTC added for P2563 - Turbocharger Boost Control Position Sensor Performance. This DTC indicates diminished variable geometry turbocharger travel, which is resolved by replacing the turbocharger. Diagnosis and repair procedures for the DTC have been published in DTC-Based Diagnostics in TechConnect. 3. The latest PCM software includes a new extended idle feature to accommodate the extended idle times present in some duty cycles. This feature may help to reduce the accumulation of soot in the exhaust aftertreatment system when the engine is idling for an extended period of time. Briefly how this feature works: a. As needed, the engine enters an idling mode which dramatically reduces the rate of soot accumulation in the diesel particulate filter (called "Net Zero"). Further, under extended idle periods of 5 minutes or longer, the engine enters a mode which reduces the amount of soot accumulated in the diesel particulate filter (called "Net Reduction"). While in these modes, the idle speed increases to 900 RPM for a period of time. The idle speed may return to normal idle speed and then return to 900 RPM to repeat this cycle during very long idle periods. b. These modes occur automatically depending on the need to regenerate the DPF as long as the vehicle is not driven over 20 MPH or operated at high load. If the vehicle is driven over 20 MPH normal mobile desoot will occur automatically. 4. New scan tool driven fuel system diagnostic tests (same as previously released in the pick up) now available for cab chassis. DIAGNOSIS: 1. Using the scan tool, determine current software level of the PCM and CCN. Record on the repair order, for later use, the current PCM and CCN software level part numbers. Proceed to the next step. 2. Compare the current PCM software level part number with software available in the scantool. Determine if the current PCM software level part number, recorded in Step # 1, is programmable to a higher level. 3. Is the part number of the current PCM level software (recorded in Step # 1) at the latest level listed in the scan tool? a. If YES >> then the PCM DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. b. If NO >> then the PCM DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. 4. Is the vehicle a 2007 OR 2008 MY? a. Yes >>> Proceed to Step # 5. b. No >>> 2009 MY proceed to the REPAIR PROCEDURE as required. 5. Determine if the current CCN module level software part number, that was recorded earlier in Step # 1, is one of the following (or with a higher suffix): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 3954 a. 05172187AH (or higher) = 2007 DC (3500). b. 05172334AG (or higher) = 2008 DC (3500) / DM (3500/4500). c. 2009 & 2010 MY vehicles came equipped with proper CCN software. 6. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 5? a. If YES >>> then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. b. If NO >>> then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. PARTS REQUIRED: REPAIR PROCEDURE; ECM MODULE REPROGRAM: NOTE: The wiTECH diagnostic application is the preferred method for flashing ECU's. Help using the wiTECH diagnostic application for flashing an ECU is available by selecting "Help" then "Help Contents" at the top of the wiTECH diagnostic application window. NOTE: The wiTECH software level must be at release 10.04 or higher to perform this procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. If required, as determined in DIAGNOSIS, above: reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > 8E - Electronic Control Modules >MODULE, Engine Control, Diesel > Service Information > Standard Procedure > PCM/ECM Programming - DIESEL. After PCM reprogramming, the following must be performed: a. Clear any DIG's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 3. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. 4. If required, as determined in DIAGNOSIS, above: reprogram the CCN using one of the following procedures, (based on scan tool use). 5. Was it determined in DIAGNOSIS, Step # 6 above, the CCN required updating? a. Yes >>> Proceed to appropriate CCN Module Reprogram Procedure Below, based on the scantool used. b. No >>> Repair is complete. NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 3955 NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. CCN MODULE REPROGRAM - USING wiTECH(R): 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id and "Password", then select "OK". 6. Select the "Next tab at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash" screen follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF position", remove the wiPOD(R) and battery charger from the vehicle. StarMOBILE(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident" flash file for statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 3956 b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step Se, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number (displayed at the end of the "Resident flash file for statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 3957 Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "Exhaust Filter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required - See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test Engine Control Module: All Technical Service Bulletins Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 3962 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 3967 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 3968 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3973 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3974 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3975 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3976 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-030-07 > Apr > 07 > Engine Controls - Engine Off Idle Speed Limit Feature Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Off Idle Speed Limit Feature NUMBER: 18-030-07 GROUP: Vehicle Performance DATE: April 26, 2007 SUBJECT: Engine Off-Idle Speed Limit Feature To Protect Turbocharger When Vehicle Is Not Moving OVERVIEW: This bulletin involves a discussion regarding an engine control feature that limits engine off-idle speeds when the vehicle is not moving. MODELS: 2004 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 5.9L or a 6.7L Cummins turbo-diesel engine (sale codes: ETC, ETH, or ETJ). DISCUSSION: Dependent upon engine coolant temperature, the Engine Control Module (ECM) will temporarily delay (limit) the maximum engine speed when the vehicle is not moving. For automatic transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph, and when the transmission selector is in either the neutral or park position. For manual transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph. This ECM feature is used to protect the engine turbocharger. By temporarily limiting the vehicle engine speed, the shaft speed of the engine turbocharger is controlled to a low speed. This delay in maximum engine and turbo-charger shaft speed allows for sufficient oil lubrication to the turbocharger shaft bearings. Satisfactory oil lubrication of the turbocharger shaft bearings is important for long term turbocharger durability. The maximum engine speed for the 5.9L engine is temporarily limited to 1,600 RPM's when the above conditions are met. The 6.7L engine speed is temporarily limited to 1,200 RPM's when the above conditions are met. The length of time that the maximum engine speed is temporarily limited is dependent upon engine coolant temperature. Refer to the table to determine the amount of Time Delay. NOTE: The time delay values supplied in the table are an approximation and may vary per application. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Engine Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 3985 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 3986 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 3987 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness Technical Service Bulletin # K01 Date: 100510 Recall - ECM Update For OBD Readiness May 2010 Dealer Service Instructions for: California Emissions Recall K01 Reprogram ECM OBD Readiness Effective immediately all repairs on involved vehicles are to be performed according to this notification. Service Bulletin 18-038-09 is no longer applicable for the involved vehicles only. Models 2003 (DR) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETC) and a California emission control system (sales code NAE). 2006-2007 (DH/D1) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETH) and a California emission control system (sales code NAE). 2007 (DC) Dodge Ram Truck (3500 series cab chassis) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ) and a California emission control system (sales code NAE) built through January 5, 2007 (MDH010508). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process or GRS DealerCONNECT functions. Subject The Engine Control Module (ECM) on about 25,208 of the above vehicles may fail to accurately report diagnostic system information with some generic scan tools. This may cause the vehicle to be rejected or fail an Inspection/Maintenance Test (also known as a Smog Check). Repair The Engine Control Module (ECM) must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Part Number Description 04275086AB Authorized Modifications Label Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 3993 The special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the label plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 3994 To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: The DRBIII(R) must be used to perform this recall on 2003 Model Year (MY) vehicles. The 2003 MY procedure is found in Section D of the Service Procedure. Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall on 2006-2007 MY vehicles. This procedure must be performed with software release level 10.03 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 3995 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's" button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section E. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 3996 h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section E. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 3997 e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 10. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 9. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 10. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 11. Continue with Section E. Install Authorized Modification Label. D. Reprogram the ECM Using DRBIII(R): The DealerCONNECT System, DRBIII(R) (Diagnostic Readout Box scan tool), CH7000A flash cable and CH7035B data cable are required to perform this repair. Do not attempt to perform the flash procedure using an outdated CH7000/CH7001 flash cable. NOTE: Whenever a controller is reprogrammed, the software in the DRBIII scan tool must be programmed with the latest revision level available. NOTE: If the flash process is interrupted or aborted, the flash should be restarted and then follow the directions on the DRBIII scan tool. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 3998 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the DRBIII CH7000A flash cable from the DRBIII scan tool to the data link connector located inside the vehicle under the steering column. 3. Connect the CH7035B data cable from the DealerCONNECT machine to the MDS port on the DRBIII scan tool. 4. Place the vehicle's ignition key in the "RUN" position. 5. From the DealerCONNECT "WELCOME" screen, enter your "User I.D.," "Password" and "Dealer Code". 6. From the DealerCONNECT "HOME PAGE" select the "SERVICE" tab. 7. From the "SERVICE" tab screen select "TechTOOLS". 8. If the DRBIII scan tool does not "Auto Connect" select # 2 on the DRBIII key pad "Connect to TechCONNECT". 9. After the "Auto Connect" process is complete, select "READ PART NUMBER(S) FROM VEHICLE" on the TechCONNECT screen. 10. Continue following the TechCONNECT on-screen instructions. 11. Select the applicable update calibration. 12. Select the "DRBIII" button located at the bottom of the TechCONNECT monitor screen. 13. Select the "DOWNLOAD / UPDATE" button located next to the "DRBIII" button. NOTE: The system software will automatically download to the DRBIII scan tool. 14. After the software download to the DRBIII scan tool is complete, close the "DOWNLOAD / UPDATE PROGRESS" window. 15. Disconnect the DRBIII scan tool from the TechCONNECT CH7035B data cable. 16. Select # 1 "RETURN TO NORMAL MODE" on the DRBIII scan tool. 17. Use the following procedure to download the flash from the DRBIII scan tool to the vehicle. a. Select # 7 "VEHICLE FLASH" on the DRBIII scan tool. b. Follow the directions displayed on the DRBIII scan tool screen. c. After the reprogramming is complete, record the new module part number displayed on the DRBIII scan tool screen. d. Press the "PAGE BACK" button on the DRBIII scan tool. 18. Due to the ECM flash procedure, Diagnostic Trouble Codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS, ORC) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules, record the trouble codes, and erase the trouble codes using the following procedure: a. Turn the vehicle's ignition key to the "RUN" position. b. From the DRBIII scan tool Main Menu select # 1 "DRBIII Stand-Alone". c. From the DRBIII scan tool Stand-Alone menu select # 3 "Vehicle Module Scan". d. From the DRBIII scan tool Vehicle Module Scan menu select # 1 "1998 - 2005 Module Scan". e. Select "YES" on the DRBIII scan tool key pad to scan for DTC's. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 3999 f. Follow the instructions on the DRBIII scan tool screen. g. Once the scanning process is complete, the DRBIII scan tool will display a list of all the modules. Modules on the list that have an asterisk next to them have DTC's that need to be cleared. h. Select the module that needs to have the DTC's cleared and follow the instructions on the DRBIII scan tool screen to clear the DTC's. i. Turn the vehicle's ignition key to the "OFF" position. NOTE: Erase any DTC's in the ECM only after all other modules have had their DTC's erased. 19. Disconnect the DRBIII scan tool from the vehicle. 20. Turn off the battery charger and disconnect it from the vehicle. 21. Continue with Section E. Install Authorized Modification Label. E. Install the Authorized Modifications Label: 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 4000 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4005 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4006 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4007 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4008 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4009 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4010 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4011 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 4020 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 4021 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 4022 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control Engine Control Module: Locations Module-Engine Control Component ID: 203 Component : MODULE-ENGINE CONTROL Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (5.9L) Pin Description Circuit 1 WASTEGATE SOLENOID CONTROL K139 18DB 2 OIL PRESSURE SIGNAL G6 18VT/GY 3-4 CAN C BUS (+) D65 18WT/LG 5 CAN C BUS (-) D64 18WT/LB 6 FUEL CONTROL ACTUATOR RETURN K65 18BR/LB 7 GEN FIELD CONTROL K20 18BR/GY 8 TTVA MOTOR (+) K314 18TN/YL 9-10 - 11 WATER IN FUEL SENSOR GROUND K923 18BR/WT 12 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 13 INLET AIR TEMPERATURE SENSE K615 18VT/WT 14 - 15 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 16 INLET AIR PRESSURE SENSE K616 18BR/YL 17 ECT SIGNAL K2 18VT/OR 18 - 19 FUEL CONTROL ACTUATOR DRIVER K604 18BR/TN 20 TTVA MOTOR (-) K315 18TN/OR 21 FAN SPEED SENSOR GROUND K161 18BR/LB 22 CKP SIGNAL K24 18BR/LB 23 SENSOR GROUND K200 18BR/YL 24 CMP SIGNAL K44 18DB/GY 25 5 VOLT SUPPLY K668 18BR 26 - 27 5 VOLT SUPPLY K853 18DB/BR 28 - 29 SENSOR GROUND K690 18BR/YL 30 INJECTOR CONTROL NO. 1 K11 16BR/YL 31 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG 32 CMP SENSOR GROUND K944 18BK/GY Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4025 33 APPS NO. 1 RETURN K167 18BR/YL 34 FAN SPEED SENSOR SIGNAL N210 18DB/DG 35 - 36 INJECTOR CONTROL NO. 4 K14 16BR/TN 37 - 38 - 39 - 40 INJECTOR CONTROL NO. 3 K13 16TN 41 SENSOR GROUND K210 18DB/TN 42 5 VOLT SUPPLY K852 18BR/VT 43 BOOST PRESSURE SENSOR SIGNAL K37 18LB 44 - 45 - 46 INJECTOR CONTROL NO. 6 K58 16BR/VT 47 - 48 - 49 - 50 INJECTOR CONTROL NO. 2 K12 16BR/DB 51 - 52 CKP SENSOR GROUND K975 18BR/OR 53 FUEL RAIL SENSOR RETURN K915 18BR/WT 54 5 VOLT SUPPLY F855 18PK/YL 55 - 56 INJECTOR CONTROL NO. 5 K38 16GY 57 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 16TN/PK 58 - 59 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 16BR/LG 60 - Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4026 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4027 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4028 Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 2 EGR CONTROL NO. 1 K682 18DB/WT 3 EGR CONTROL NO. 2 K684 18DB/YL 4 EGR CONTROL NO. 3 K686 18GY/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4029 5 EGR SIGNAL NO. 2 K685 18DB 6-7 FAN SPEED SENSOR GROUND K161 18BR/LB 8-9 EGR BYPASS VALVE SIGNAL K670 18BR/LB 10 FUEL CONTROL ACTUATOR RETURN K366 18BR/LB 11 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 12 - 13 EGR AIRFLOW CONTROL VALVE MOTOR (-) K314 18BR 14 CRANKCASE SENSOR SIGNAL K926 18DB/GY 15 ECT SIGNAL K2 18VT/OR 16 - 17 EGR BYPASS STATUS K671 18BR/DB 18 FAN SPEED SENSOR SIGNAL N27 18DB/GY 19 BOOST PRESSURE SENSOR SIGNAL K37 18BR 20 INLET AIR PRESSURE SENSE K616 18BR/YL 21 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 22 SENSOR GROUND K971 18BR/PK 23 - 24 INLET AIR TEMPERATURE SENSE K615 18VT/WT 25 EGR SIGNAL NO. 1 K683 18DB/GY 26 5 VOLT SUPPLY K824 18DB/BR 27 EGR AIRFLOW CONTROL VALVE MOTOR (+) K158 18BR/YL 28 GEN SENSE A804 18RD 29 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 30 FUEL CONTROL ACTUATOR DRIVER K365 18DB/BR 31 CKP SIGNAL K24 18BR/LB 32 OIL PRESSURE SIGNAL G6 18VT/GY 33 ACTUATOR GROUND K972 18DB/TN 34 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG 35 EGR SIGNAL NO. 3 K687 18DB/LB 36 5 VOLT SUPPLY F855 18PK/YL 37 CMP SIGNAL K44 18DB/GY 38 ACTUATOR HIGH DATA LINK D130 18BR/VT 39 ACTUATOR LOW DATA LINK D131 18WT/LG 40 GEN FIELD CONTROL K20 18BR/GY 41 EGR TEMPERATURE SENSOR SIGNAL K935 18DB 42 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 43 TURBO SPEED SENSOR GROUND K541 18BR/VT 44 CKP SENSOR GROUND K925 18BR/OR 45 INJECTOR CONTROL NO. 6 K58 16BR/VT 46 INJECTOR CONTROL NO. 2 K12 16BR/DB 47 SENSOR GROUND K914 18BR/WT 48 SENSOR GROUND K916 18BR/OR 49 - 50 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG 51 INJECTOR HIGH SIDE DRIVER NO. 3 K613 16GY/BR 52 INJECTOR HIGH SIDE DRIVER NO. 2 K612 16YL/BR 53 INJECTOR HIGH SIDE DRIVER NO. 1 K611 16OR/BR 54 INJECTOR CONTROL NO. 4 K14 16BR/TN 55 INJECTOR CONTROL NO. 5 K38 16GY 56 INJECTOR CONTROL NO. 3 K13 16TN 57 INJECTOR CONTROL NO. 1 K11 16BR/YL 58 INJECTOR HIGH SIDE DRIVER NO. 6 K658 16LG/BR 59 INJECTOR HIGH SIDE DRIVER NO. 5 K638 16LB/BR 60 INJECTOR HIGH SIDE DRIVER NO. 4 K614 16WT/BR Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4030 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4031 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4032 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 50 Qualifier : (5.9L) Pin Description Circuit 1-2-3 APPS NO. 1 SIGNAL K23 18BR/WT 4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4033 5 TRANSMISSION CONTROL T515 18YL/DB 6 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 7 FUEL PUMP CONTROL K31 18BR 8-9 TRS T41 SIGNAL (P/N) T41 18YL/DB 10 - 11 - 12 - 13 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 18DG 14 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 15 3-4 SOLENOID CONTROL T9 18DG/TN 16 - 17 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 18 - 19 - 20 FUSED B(+) A209 16RD 21 GROUND Z902 16BK 22 - 23 5 VOLT SUPPLY F856 18YL/PK 24 SENSOR GROUND K900 18DB/DG 25 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 26 - 27 TTVA POSITION SENSOR SIGNAL K312 18OR 28 - 29 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR 30 FUSED B(+) A209 16RD 31 - 32 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 33 5 VOLT SUPPLY K854 18VT/BR 34 - 35 APPS NO. 2 SIGNAL K29 18WT/BR 36 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 37 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 38 - 39 - 40 FUSED B(+) A209 16RD 41 A/C CLUTCH CONTROL C13 18LB/OR 42 - 43 PWM FAN COIL SIGNAL K160 18BR/OR 44 OUTPUT SPEED SIGNAL T14 18DG/BR 45 SPEED SENSOR GROUND T13 18DG/VT 46 S/C SWITCH NO. 1 SIGNAL V37 18VT 47 BATT TEMP SIGNAL K25 18DB/VT 48 APPS NO. 2 RETURN K400 18BR/VT 49 GROUND Z902 16BK 50 GROUND Z902 16BK Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4034 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4035 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4036 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 CAN C BUS (+) D65 18WT/LG 2 FUEL PUMP CONTROL K31 18BR 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4037 5 EXHAUST BRAKE SWITCH SIGNAL G905 18BR/OR 6 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 7 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 8 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 9 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/OR 10 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 11 - 12 - 13 - 14 - 15 CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT T26 18DG/OR 16 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 17 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 18 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 19 - 20 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 21 CAN C BUS (-) D64 18WT/LB 22 APPS NO. 2 RETURN K400 18BR/VT 23 - 24 APPS NO. 2 SIGNAL K29 18WT/BR 25 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 26 5 VOLT SUPPLY K854 18VT/BR 27 5 VOLT SUPPLY K852 18BR/LB 28 APPS NO. 1 RETURN K167 18BR/DG 29 SENSOR GROUND K900 18DB/DG 30 BATT TEMP SIGNAL K25 18DB/VT 31 DIAGNOSTIC PORT HIGH DATA LINK D133 18WT/OR 32 - 33 S/C SWITCH RETURN V937 18VT/BR 34 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 35 APPS NO. 1 SIGNAL K23 18BR/WT 36 - - 37 REMOTE THROTTLE SIGNAL K128 18DG/LG 38 - 39 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 40 S/C SWITCH NO. 1 SIGNAL V37 18VT 41 - 42 - 43 SMART POWER RELAY RETURN K348 18BR 44 A/C CLUTCH CONTROL C13 18LB 45 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 46 - 47 GROUND Z902 16BK 48 GROUND Z902 16BK 49 FUSED B(+) A209 16RD 50 FUSED B(+) A209 16RD 51 DIAGNOSTIC PORT LOW DATA LINK D132 18WT 52 - 53 - 54 EXHAUST BRAKE LAMP SIGNAL G904 18VT/DG 55 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 56 S/C SWITCH NO. 2 SIGNAL V38 18VT/OR 57 GROUND Z902 16BK 58 - 59 - 60 FUSED B(+) A209 16RD Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4038 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4039 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4040 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4041 Engine Control Module: Locations Module-Powertrain Control Component ID: 209 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Pin Description Circuit 123456- 789-10 11 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (RUN-START) F1 20PK/WT 13 14 15 16 17 18 - 19 SENSOR GROUND T160 20DG/WT 20 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 21 22 23 24 25 26 - 27 5 VOLT SUPPLY F856 20YL/PK 28 29 FUSED B(+) A918 20RD 30 IGNITION START T751 20YL 31 32 - Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4042 33 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 38 Component Location - 29 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4043 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 8 K98 18DB/YL 2-3 COIL CONTROL NO. 7 K97 18DB/YL 3 COIL CONTROL NO. 7 K97 18BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4044 4 INJECTOR CONTROL NO. 8 K28 18BR/LB 5 INJECTOR CONTROL NO. 7 K26 18BR/YL 6-7-8-9 GROUND Z130 16BK/BR 10 FUSED B(+) A918 16RD 11 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 13 - 14 - 15 - 16 - 17 - 18 GROUND Z131 16BK/DG 19 GROUND Z951 16BK/YL 20 OIL PRESSURE SIGNAL G6 16VT/GY 21 - 22 - 23 - 24 GEN SENSE A804 18RD/GY 25 - 27 5 VOLT SUPPLY F856 20YL/PK 28 MDS SOL CONTROL NO. 4 K452 20BR/LB 29 FUSED B(+) A918 16RD 30 IGNITION START T751 20YL 31 O2 1/2 SIGNAL K141 20DB/YL 32 O2 1/1 RETURN K902 20BR/DG 33 O2 2/2 SIGNAL K243 20BR 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 - - 38 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4045 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4046 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 6 K10 18DB/OR 2 COIL CONTROL NO. 5 K16 18DB/YL 3 COIL CONTROL NO. 4 K15 18DB/GY 4 INJECTOR CONTROL NO. 6 K58 18BR/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4047 5 INJECTOR CONTROL NO. 5 K38 18BR/OR 6 ETC MOTOR (+) K447 20TN/YL 7 COIL CONTROL NO. 3 K18 18DB/OR 8 EGR SOL CONTROL K35 20DB/VT 9 COIL CONTROL NO. 2 K17 18DB/TN 10 COIL CONTROL NO. 1 K19 18DB/DG 11 INJECTOR CONTROL NO. 4 K14 18BR/TN 12 INJECTOR CONTROL NO. 3 K13 18BR/LB 13 INJECTOR CONTROL NO. 2 K12 18BR/DB 14 INJECTOR CONTROL NO. 1 K11 18BR/YL 15 TP SENSOR RETURN K922 20BR/DB 16 MDS SOL CONTROL NO. 6 K453 20BR/DG 17 O2 2/1 HEATER CONTROL K199 20BR/VT 18 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 19 GEN FIELD CONTROL K20 18BR/GY 20 ECT SIGNAL K2 20VT/OR 21 TP NO. 1 SIGNAL K22 20BR/OR 22 EGR SIGNAL K34 20DB/LG 23 MAP SIGNAL K1 20VT/BR 24 KNOCK SENSOR NO. 1 RETURN K942 20BR/LG 25 KNOCK SENSOR NO. 1 SIGNAL K42 20DB/YL 26 - 27 SENSOR GROUND K900 20DB/DG 28 TP NO. 2 SIGNAL K122 20BR/DG 28 IAC SIGNAL K961 20BR/VT 29 5 VOLT SUPPLY F855 20PK/YL 30 IAT SIGNAL K21 20DB/LG 31 O2 1/1 SIGNAL K41 20DB/LB 32 O2 1/2 RETURN K904 20DB/DG 33 O2 2/1 SIGNAL K43 20DB/LG 34 CMP SIGNAL K44 20DB/GY 35 CKP SIGNAL K24 20BR/LB 36 KNOCK SENSOR NO. 2 SIGNAL K242 20BR/WT 37 KNOCK SENSOR NO. 2 RETURN K924 20WT/BR 38 ETC MOTOR (-) K448 20TN/OR 38 IAC CONTROL K61 20VT/GY Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4048 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4049 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1-2-3 ASD CONTROL K51 20BR/WT 4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4050 5 S/C VENT SOL CONTROL V35 20VT/OR 5 MDS SOL CONTROL NO. 7 K454 20BR/OR 6 MDS SOL CONTROL NO. 1 K451 20BR/WT 7 SPEED CONTROL SUPPLY V32 20VT/YL 8-9 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 10 O2 2/2 HEATER CONTROL K399 18BR/GY 11 A/C CLUTCH CONTROL C13 20LB/OR 12 S/C VACUUM SOL CONTROL V36 20VT/YL 13 - 14 BRAKE SWITCH NO. 2 SIGNAL V32 20VT/YL 15 S/C SWITCH RETURN V937 20VT/BR 16 APPS NO. 1 RETURN K167 20BR/YL 17 APPS NO. 2 RETURN K400 20BR/VT 18 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 19 ASD CONTROL OUTPUT K342 16BR/WT 20 EVAP PURGE SOL CONTROL K52 20DB/WT 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 PTO SENSE G113 20VT 22 PTO SENSE G113 18PK/YL 23 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT 24 - 25 APPS NO. 1 SIGNAL K23 20BR/WT 26 - 27 - 28 ASD CONTROL OUTPUT K342 16BR/WT 29 EVAP PURGE SOL SIGNAL K70 20DB/BR 30 P/S SWITCH SIGNAL K66 20DB/WT 31 - 32 - 33 OIL TEMPERATURE SIGNAL G24 20VT/BR 34 S/C SWITCH NO. 1 SIGNAL V37 20VT 35 ESM SIGNAL K107 20VT/WT 36 APPS NO. 2 SIGNAL K29 20WT/BR 37 FUEL PUMP CONTROL K31 20BR 38 STARTER SOLENOID CONTROL T752 20DG/OR Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4051 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4052 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Description Circuit 1 SENSOR GROUND T160 20YL/GY 2 4C CONTROL T259 20YL/DG 34 MS CONTROL T140 20YL/GY Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4053 5- 6 2C CONTROL T219 20YL/LG 78 UD CONTROL T59 20YL/LB 910 L/R CONTROL T20 20DG/BK 11 LINE PRESSURE CONTROL T118 20DG 12 GROUND Z133 18BK/LG 13 GROUND Z133 18BK/LG 14 GROUND Z133 18BK/LG 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 24 25 26 TRS T2 SIGNAL T4 20DG/LB 27 TRS T41 SIGNAL (P/N) T41 20YL/DB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4054 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4055 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 OD SOLENOID CONTROL T60 20YL/GY 2 4C CONTROL T259 20YL/DG 2 UD CONTROL T59 20YL/LB 3-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4056 4 MS CONTROL T140 20YL/GY 5-6 2C CONTROL T219 20YL/LG 6 2-4 SOLENOID CONTROL T19 18YL/DB 7-8 UD CONTROL T59 20YL/LB 9-10 L/R CONTROL T20 20DG/WT 11 PRESSURE CONTROL SOLENOID CONTROL T118 20DG 12 GROUND Z908 18BK 13 GROUND Z977 18BK 14 GROUND Z904 18BK 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 - 24 - 25 - 26 TRS T2 SIGNAL T4 20DG/LB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 30 2-4 PRESSURE SWITCH SENSE T47 18YL/DG 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4057 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4058 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4061 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4062 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4063 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4064 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4065 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4066 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4067 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4068 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4069 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4070 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4071 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4072 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4073 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4074 Engine Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4075 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4076 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4077 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4078 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4079 Engine Control Module: Connector Views Module-Engine Control Component ID: 203 Component : MODULE-ENGINE CONTROL Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (5.9L) Pin Description Circuit 1 WASTEGATE SOLENOID CONTROL K139 18DB 2 OIL PRESSURE SIGNAL G6 18VT/GY 3-4 CAN C BUS (+) D65 18WT/LG 5 CAN C BUS (-) D64 18WT/LB 6 FUEL CONTROL ACTUATOR RETURN K65 18BR/LB 7 GEN FIELD CONTROL K20 18BR/GY 8 TTVA MOTOR (+) K314 18TN/YL 9-10 - 11 WATER IN FUEL SENSOR GROUND K923 18BR/WT 12 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 13 INLET AIR TEMPERATURE SENSE K615 18VT/WT 14 - 15 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 16 INLET AIR PRESSURE SENSE K616 18BR/YL 17 ECT SIGNAL K2 18VT/OR 18 - 19 FUEL CONTROL ACTUATOR DRIVER K604 18BR/TN 20 TTVA MOTOR (-) K315 18TN/OR 21 FAN SPEED SENSOR GROUND K161 18BR/LB 22 CKP SIGNAL K24 18BR/LB 23 SENSOR GROUND K200 18BR/YL 24 CMP SIGNAL K44 18DB/GY 25 5 VOLT SUPPLY K668 18BR 26 - 27 5 VOLT SUPPLY K853 18DB/BR 28 - 29 SENSOR GROUND K690 18BR/YL 30 INJECTOR CONTROL NO. 1 K11 16BR/YL 31 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4080 32 CMP SENSOR GROUND K944 18BK/GY 33 APPS NO. 1 RETURN K167 18BR/YL 34 FAN SPEED SENSOR SIGNAL N210 18DB/DG 35 - 36 INJECTOR CONTROL NO. 4 K14 16BR/TN 37 - 38 - 39 - 40 INJECTOR CONTROL NO. 3 K13 16TN 41 SENSOR GROUND K210 18DB/TN 42 5 VOLT SUPPLY K852 18BR/VT 43 BOOST PRESSURE SENSOR SIGNAL K37 18LB 44 - 45 - 46 INJECTOR CONTROL NO. 6 K58 16BR/VT 47 - 48 - 49 - 50 INJECTOR CONTROL NO. 2 K12 16BR/DB 51 - 52 CKP SENSOR GROUND K975 18BR/OR 53 FUEL RAIL SENSOR RETURN K915 18BR/WT 54 5 VOLT SUPPLY F855 18PK/YL 55 - 56 INJECTOR CONTROL NO. 5 K38 16GY 57 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 16TN/PK 58 - 59 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 16BR/LG 60 - Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4081 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4082 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4083 Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 2 EGR CONTROL NO. 1 K682 18DB/WT 3 EGR CONTROL NO. 2 K684 18DB/YL 4 EGR CONTROL NO. 3 K686 18GY/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4084 5 EGR SIGNAL NO. 2 K685 18DB 6-7 FAN SPEED SENSOR GROUND K161 18BR/LB 8-9 EGR BYPASS VALVE SIGNAL K670 18BR/LB 10 FUEL CONTROL ACTUATOR RETURN K366 18BR/LB 11 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 12 - 13 EGR AIRFLOW CONTROL VALVE MOTOR (-) K314 18BR 14 CRANKCASE SENSOR SIGNAL K926 18DB/GY 15 ECT SIGNAL K2 18VT/OR 16 - 17 EGR BYPASS STATUS K671 18BR/DB 18 FAN SPEED SENSOR SIGNAL N27 18DB/GY 19 BOOST PRESSURE SENSOR SIGNAL K37 18BR 20 INLET AIR PRESSURE SENSE K616 18BR/YL 21 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 22 SENSOR GROUND K971 18BR/PK 23 - 24 INLET AIR TEMPERATURE SENSE K615 18VT/WT 25 EGR SIGNAL NO. 1 K683 18DB/GY 26 5 VOLT SUPPLY K824 18DB/BR 27 EGR AIRFLOW CONTROL VALVE MOTOR (+) K158 18BR/YL 28 GEN SENSE A804 18RD 29 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 30 FUEL CONTROL ACTUATOR DRIVER K365 18DB/BR 31 CKP SIGNAL K24 18BR/LB 32 OIL PRESSURE SIGNAL G6 18VT/GY 33 ACTUATOR GROUND K972 18DB/TN 34 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG 35 EGR SIGNAL NO. 3 K687 18DB/LB 36 5 VOLT SUPPLY F855 18PK/YL 37 CMP SIGNAL K44 18DB/GY 38 ACTUATOR HIGH DATA LINK D130 18BR/VT 39 ACTUATOR LOW DATA LINK D131 18WT/LG 40 GEN FIELD CONTROL K20 18BR/GY 41 EGR TEMPERATURE SENSOR SIGNAL K935 18DB 42 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 43 TURBO SPEED SENSOR GROUND K541 18BR/VT 44 CKP SENSOR GROUND K925 18BR/OR 45 INJECTOR CONTROL NO. 6 K58 16BR/VT 46 INJECTOR CONTROL NO. 2 K12 16BR/DB 47 SENSOR GROUND K914 18BR/WT 48 SENSOR GROUND K916 18BR/OR 49 - 50 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG 51 INJECTOR HIGH SIDE DRIVER NO. 3 K613 16GY/BR 52 INJECTOR HIGH SIDE DRIVER NO. 2 K612 16YL/BR 53 INJECTOR HIGH SIDE DRIVER NO. 1 K611 16OR/BR 54 INJECTOR CONTROL NO. 4 K14 16BR/TN 55 INJECTOR CONTROL NO. 5 K38 16GY 56 INJECTOR CONTROL NO. 3 K13 16TN 57 INJECTOR CONTROL NO. 1 K11 16BR/YL 58 INJECTOR HIGH SIDE DRIVER NO. 6 K658 16LG/BR 59 INJECTOR HIGH SIDE DRIVER NO. 5 K638 16LB/BR 60 INJECTOR HIGH SIDE DRIVER NO. 4 K614 16WT/BR Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4085 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4086 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4087 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 50 Qualifier : (5.9L) Pin Description Circuit 1-2-3 APPS NO. 1 SIGNAL K23 18BR/WT 4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4088 5 TRANSMISSION CONTROL T515 18YL/DB 6 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 7 FUEL PUMP CONTROL K31 18BR 8-9 TRS T41 SIGNAL (P/N) T41 18YL/DB 10 - 11 - 12 - 13 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 18DG 14 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 15 3-4 SOLENOID CONTROL T9 18DG/TN 16 - 17 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 18 - 19 - 20 FUSED B(+) A209 16RD 21 GROUND Z902 16BK 22 - 23 5 VOLT SUPPLY F856 18YL/PK 24 SENSOR GROUND K900 18DB/DG 25 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 26 - 27 TTVA POSITION SENSOR SIGNAL K312 18OR 28 - 29 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR 30 FUSED B(+) A209 16RD 31 - 32 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 33 5 VOLT SUPPLY K854 18VT/BR 34 - 35 APPS NO. 2 SIGNAL K29 18WT/BR 36 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 37 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 38 - 39 - 40 FUSED B(+) A209 16RD 41 A/C CLUTCH CONTROL C13 18LB/OR 42 - 43 PWM FAN COIL SIGNAL K160 18BR/OR 44 OUTPUT SPEED SIGNAL T14 18DG/BR 45 SPEED SENSOR GROUND T13 18DG/VT 46 S/C SWITCH NO. 1 SIGNAL V37 18VT 47 BATT TEMP SIGNAL K25 18DB/VT 48 APPS NO. 2 RETURN K400 18BR/VT 49 GROUND Z902 16BK 50 GROUND Z902 16BK Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4089 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4090 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4091 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 CAN C BUS (+) D65 18WT/LG 2 FUEL PUMP CONTROL K31 18BR 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4092 5 EXHAUST BRAKE SWITCH SIGNAL G905 18BR/OR 6 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 7 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 8 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 9 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/OR 10 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 11 - 12 - 13 - 14 - 15 CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT T26 18DG/OR 16 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 17 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 18 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 19 - 20 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 21 CAN C BUS (-) D64 18WT/LB 22 APPS NO. 2 RETURN K400 18BR/VT 23 - 24 APPS NO. 2 SIGNAL K29 18WT/BR 25 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 26 5 VOLT SUPPLY K854 18VT/BR 27 5 VOLT SUPPLY K852 18BR/LB 28 APPS NO. 1 RETURN K167 18BR/DG 29 SENSOR GROUND K900 18DB/DG 30 BATT TEMP SIGNAL K25 18DB/VT 31 DIAGNOSTIC PORT HIGH DATA LINK D133 18WT/OR 32 - 33 S/C SWITCH RETURN V937 18VT/BR 34 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 35 APPS NO. 1 SIGNAL K23 18BR/WT 36 - - 37 REMOTE THROTTLE SIGNAL K128 18DG/LG 38 - 39 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 40 S/C SWITCH NO. 1 SIGNAL V37 18VT 41 - 42 - 43 SMART POWER RELAY RETURN K348 18BR 44 A/C CLUTCH CONTROL C13 18LB 45 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 46 - 47 GROUND Z902 16BK 48 GROUND Z902 16BK 49 FUSED B(+) A209 16RD 50 FUSED B(+) A209 16RD 51 DIAGNOSTIC PORT LOW DATA LINK D132 18WT 52 - 53 - 54 EXHAUST BRAKE LAMP SIGNAL G904 18VT/DG 55 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 56 S/C SWITCH NO. 2 SIGNAL V38 18VT/OR 57 GROUND Z902 16BK 58 - 59 - 60 FUSED B(+) A209 16RD Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4093 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4094 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4095 Module-Powertrain Control Component ID: 209 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4096 Pin Description Circuit 123456789-10 11 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (RUN-START) F1 20PK/WT 13 14 15 16 17 18 - 19 SENSOR GROUND T160 20DG/WT 20 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 21 22 23 24 25 26 - 27 5 VOLT SUPPLY F856 20YL/PK 28 29 FUSED B(+) A918 20RD 30 IGNITION START T751 20YL 31 - 32 33 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 38 Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4097 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4098 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 8 K98 18DB/YL 2-3 COIL CONTROL NO. 7 K97 18DB/YL 3 COIL CONTROL NO. 7 K97 18BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4099 4 INJECTOR CONTROL NO. 8 K28 18BR/LB 5 INJECTOR CONTROL NO. 7 K26 18BR/YL 6-7-8-9 GROUND Z130 16BK/BR 10 FUSED B(+) A918 16RD 11 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 13 - 14 - 15 - 16 - 17 - 18 GROUND Z131 16BK/DG 19 GROUND Z951 16BK/YL 20 OIL PRESSURE SIGNAL G6 16VT/GY 21 - 22 - 23 - 24 GEN SENSE A804 18RD/GY 25 - 27 5 VOLT SUPPLY F856 20YL/PK 28 MDS SOL CONTROL NO. 4 K452 20BR/LB 29 FUSED B(+) A918 16RD 30 IGNITION START T751 20YL 31 O2 1/2 SIGNAL K141 20DB/YL 32 O2 1/1 RETURN K902 20BR/DG 33 O2 2/2 SIGNAL K243 20BR 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 - - 38 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4100 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4101 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 6 K10 18DB/OR 2 COIL CONTROL NO. 5 K16 18DB/YL 3 COIL CONTROL NO. 4 K15 18DB/GY 4 INJECTOR CONTROL NO. 6 K58 18BR/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4102 5 INJECTOR CONTROL NO. 5 K38 18BR/OR 6 ETC MOTOR (+) K447 20TN/YL 7 COIL CONTROL NO. 3 K18 18DB/OR 8 EGR SOL CONTROL K35 20DB/VT 9 COIL CONTROL NO. 2 K17 18DB/TN 10 COIL CONTROL NO. 1 K19 18DB/DG 11 INJECTOR CONTROL NO. 4 K14 18BR/TN 12 INJECTOR CONTROL NO. 3 K13 18BR/LB 13 INJECTOR CONTROL NO. 2 K12 18BR/DB 14 INJECTOR CONTROL NO. 1 K11 18BR/YL 15 TP SENSOR RETURN K922 20BR/DB 16 MDS SOL CONTROL NO. 6 K453 20BR/DG 17 O2 2/1 HEATER CONTROL K199 20BR/VT 18 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 19 GEN FIELD CONTROL K20 18BR/GY 20 ECT SIGNAL K2 20VT/OR 21 TP NO. 1 SIGNAL K22 20BR/OR 22 EGR SIGNAL K34 20DB/LG 23 MAP SIGNAL K1 20VT/BR 24 KNOCK SENSOR NO. 1 RETURN K942 20BR/LG 25 KNOCK SENSOR NO. 1 SIGNAL K42 20DB/YL 26 - 27 SENSOR GROUND K900 20DB/DG 28 TP NO. 2 SIGNAL K122 20BR/DG 28 IAC SIGNAL K961 20BR/VT 29 5 VOLT SUPPLY F855 20PK/YL 30 IAT SIGNAL K21 20DB/LG 31 O2 1/1 SIGNAL K41 20DB/LB 32 O2 1/2 RETURN K904 20DB/DG 33 O2 2/1 SIGNAL K43 20DB/LG 34 CMP SIGNAL K44 20DB/GY 35 CKP SIGNAL K24 20BR/LB 36 KNOCK SENSOR NO. 2 SIGNAL K242 20BR/WT 37 KNOCK SENSOR NO. 2 RETURN K924 20WT/BR 38 ETC MOTOR (-) K448 20TN/OR 38 IAC CONTROL K61 20VT/GY Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4103 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4104 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1-2-3 ASD CONTROL K51 20BR/WT 4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4105 5 S/C VENT SOL CONTROL V35 20VT/OR 5 MDS SOL CONTROL NO. 7 K454 20BR/OR 6 MDS SOL CONTROL NO. 1 K451 20BR/WT 7 SPEED CONTROL SUPPLY V32 20VT/YL 8-9 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 10 O2 2/2 HEATER CONTROL K399 18BR/GY 11 A/C CLUTCH CONTROL C13 20LB/OR 12 S/C VACUUM SOL CONTROL V36 20VT/YL 13 - 14 BRAKE SWITCH NO. 2 SIGNAL V32 20VT/YL 15 S/C SWITCH RETURN V937 20VT/BR 16 APPS NO. 1 RETURN K167 20BR/YL 17 APPS NO. 2 RETURN K400 20BR/VT 18 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 19 ASD CONTROL OUTPUT K342 16BR/WT 20 EVAP PURGE SOL CONTROL K52 20DB/WT 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 PTO SENSE G113 20VT 22 PTO SENSE G113 18PK/YL 23 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT 24 - 25 APPS NO. 1 SIGNAL K23 20BR/WT 26 - 27 - 28 ASD CONTROL OUTPUT K342 16BR/WT 29 EVAP PURGE SOL SIGNAL K70 20DB/BR 30 P/S SWITCH SIGNAL K66 20DB/WT 31 - 32 - 33 OIL TEMPERATURE SIGNAL G24 20VT/BR 34 S/C SWITCH NO. 1 SIGNAL V37 20VT 35 ESM SIGNAL K107 20VT/WT 36 APPS NO. 2 SIGNAL K29 20WT/BR 37 FUEL PUMP CONTROL K31 20BR 38 STARTER SOLENOID CONTROL T752 20DG/OR Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4106 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4107 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Description Circuit 1 SENSOR GROUND T160 20YL/GY 2 4C CONTROL T259 20YL/DG 34 MS CONTROL T140 20YL/GY Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4108 5- 6 2C CONTROL T219 20YL/LG 78 UD CONTROL T59 20YL/LB 910 L/R CONTROL T20 20DG/BK 11 LINE PRESSURE CONTROL T118 20DG 12 GROUND Z133 18BK/LG 13 GROUND Z133 18BK/LG 14 GROUND Z133 18BK/LG 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 24 25 26 TRS T2 SIGNAL T4 20DG/LB 27 TRS T41 SIGNAL (P/N) T41 20YL/DB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4109 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4110 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 OD SOLENOID CONTROL T60 20YL/GY 2 4C CONTROL T259 20YL/DG 2 UD CONTROL T59 20YL/LB 3-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4111 4 MS CONTROL T140 20YL/GY 5-6 2C CONTROL T219 20YL/LG 6 2-4 SOLENOID CONTROL T19 18YL/DB 7-8 UD CONTROL T59 20YL/LB 9-10 L/R CONTROL T20 20DG/WT 11 PRESSURE CONTROL SOLENOID CONTROL T118 20DG 12 GROUND Z908 18BK 13 GROUND Z977 18BK 14 GROUND Z904 18BK 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 - 24 - 25 - 26 TRS T2 SIGNAL T4 20DG/LB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 30 2-4 PRESSURE SWITCH SENSE T47 18YL/DG 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4112 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4113 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description Engine Control Module: Description and Operation Description DESCRIPTION CUMMINS FUEL SYSTEM COMPONENTS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 4116 The Engine Control Module (ECM) for the 5.9L diesel engine (16) is bolted to the left side of the engine below the intake manifold. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 4117 Engine Control Module: Description and Operation Operation OPERATION The main function of the Engine Control Module (ECM) is to electrically control the fuel system. The ECM also controls certain transmission and other functions previously controlled by the Powertrain Control Module (PCM). The ECM can adapt its programming to meet changing operating conditions. The ECM receives input signals from various switches and sensors. Based on these inputs, the ECM regulates various engine and vehicle operations through different system components. These components are referred to as ECM Outputs. The sensors and switches that provide inputs to the ECM are considered ECM Inputs. NOTE: ECM Inputs: - Accelerator Pedal Position Sensor (APPS) Signals #1 and #2 - AC system pressure - Auto shutdown (ASD) sense - Battery temperature - Battery temperature sensor - Battery voltage - Brake switch - Camshaft Position Sensor (CMP) - Crankshaft Position Sensor (CKP) - Data link connection for a scan tool - Engine Coolant Temperature (ECT) sensor - EATX module (if equipped) - Fuel level - Fuel pressure sensor - Fan speed (engine cooling fan) - Generator (battery voltage) output - Governor pressure (Auto. trans.) - Ground circuits - Inlet air temperature sensor/pressure sensor - Intake air temperature sensor/MAP sensor - CAN C BUS (+) circuits - CAN C BUS (-) circuits - Key switch (ignition) - Oil Pressure switch - Overdrive switch (automatic transmission only) - Park/neutral switch (auto. trans. only) - Power ground - SCI datalink bus (+) circuits - SCI datalink bus (-) circuits - Sensor return - Signal ground - Speed control multiplexed single wire input - Transfer case switch (4WD range position) - Transmission governor psi (automatic transmission only) - Transmission OSS (automatic transmission only) - Transmission oil pressure (automatic transmission only) - Transmission oil temperature (automatic transmission only) - Transmission throttle valve position (automatic transmission only) - Vehicle speed signal - Water-In-Fuel (WIF) sensor NOTE: ECM Outputs: After inputs are received by the ECM, certain sensors, switches and components are controlled or regulated by the ECM. These are considered ECM Outputs. These outputs are for: - A/C clutch relay - Auto shutdown (ASD) relay - Data link connection for diagnostic scan tool - Fan clutch PWM Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 4118 - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel control actuator - Fuel injector driver circuits - Fuel transfer (lift) pump - Generator field driver (-) - Generator field driver (+) - Governor pressure (VFS solenoid) - Intake manifold air heater relays #1 and #2 control circuits - CAN C BUS (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oil pressure switch/warning lamp (databus) - Overdrive/3-4 shift solenoid (automatic transmission only) - SC source - SCI datalink bus (+) circuits - SCI datalink bus (-) circuits - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - TCC solenoid (automatic transmission only) - Transmission battery relay (automatic transmission only) - Transmission throttle valve actuator (automatic transmission only) - Transmission governor solenoid (automatic transmission only) - Wait-to-start warning lamp (databus) - Turbo wastegate solenoid - Water-In-Fuel (WIF) warning lamp (databus) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming Engine Control Module: Testing and Inspection PCM/ECM Programming PCM/ECM REPROGRAMMING MODULE REPROGRAMING Replacement PCM's will require programming utilizing the StarSCAN(R) or equivalent. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. SPECIAL TOOLS/EQUIPMENT OR EQUIVALENT REQUIRED: **REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The StarSCAN(R) or equivalent diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) or equivalent for your dealership's network. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9410 StarSCAN(R) or equivalent ethernet cable to the StarSCAN(R) or equivalent and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 4. Power ON the StarSCAN(R) or equivalent. 5. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. 6. Replace the PCM with the appropriate Generic PCM. 7. Program the PCM as follows: a. Using the StarSCAN(R) or equivalent at the "Home" screen, Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File". Follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 4121 f. Highlight the appropriate calibration based on the part number recorded in Step 5. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. 8. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 9. b. No >> go to STEP 10. 9. Program the PCM to the Wireless Control Module (WCM). a. Highlight the WCM. b. Select "Misc. Function". c. Highlight "PCM Replaced". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step. f. When complete proceed to STEP 11. 10. Program the VIN into the PCM. a. Scroll through the list of controllers and highlight the PCM. b. Select "Misc. Function". c. Highlight "Check PCM VIN". d. Select "Start". e. Follow the on screen instructions. Select "Next" after each step . When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 11. Is the vehicle equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 13. b. No >> go to STEP 12. 12. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select ECU View b. Scroll through the list of controllers and highlight the PCM. c. Select Misc. Function. d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select Next after each step . Select Finish after completing the last step. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the Home screen select System View. Then select All DTCs. Press Clear All Stored DTCs if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label . REPAIR PROCEDURE USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 4122 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 3. Power ON the StarSCAN(R) or equivalent. 4. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. 5. Replace the PCM with the appropriate Generic PCM. 6. Insert the StarSCAN(R) or equivalent Software Update CD into the Techconnect or equivalent PC. The StarSCAN(R) or equivalent Software Update CD will start automatically. Select "Download Flash Updates". 7. At the "Select a method for looking up controller flash updates." screen: a. Select "Enter part number". Enter the "Part Number" recorded in STEP 4 when prompted to do so. b. Using the mouse highlight the appropriate "Calibration". Select "Next". c. Follow the on screen instructions. d. When completed, proceed to STEP 8. 8. With the StarSCAN(R) or equivalent powered OFF, connect the USB Key and Gender Changer to the StarSCAN(R) or equivalent USB port . 9. Connect the StarSCAN(R) or equivalent to the vehicle (if not already connected). 10. Power ON the StarSCAN(R) or equivalent. 11. Download the flash file from the USB key to the StarSCAN(R) or equivalent. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "Flash Download", then select "Retrieve files from the USB storage device" b. Highlight the appropriate calibration. Select "Download to Scan Tool" c. When the download is complete, select "Close" and "Back". 12. Reprogram the ECU. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View". b. Select More Options". c. Select "ECU Flash". d. Highlight the appropriate calibration. e. Select "Update Controller". Follow the on screen instructions. f. When the update is complete, select "OK". g. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 4123 13. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 14. b. No >> go to STEP 15. 14. Program the PCM to the Wireless Control Module (WCM). Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the WCM. c. Select "Misc. Function". d. Highlight "PCM Replaced". e. Select "Start". f. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step. g. When complete proceed to STEP 16. 15. Program the VIN into the PCM. a. Scroll through the list of controllers and highlight the PCM. b. Select "Misc. Function". c. Highlight "Check PCM VIN". d. Select "Start". e. Follow the on screen instructions. Select "Next" after each step . When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 16. Is the vehicle equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 18. b. No >> go to STEP 17. 17. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the PCM. c. Select "Misc. Function". d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "ECU View" from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 18. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label . Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 4124 Engine Control Module: Testing and Inspection SKREEM Programming SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: 1. Program the new PCM/ECM. 2. Program the new SKREEM/WCM. 3. Replace all ignition keys and program them into the new SKREEM/WCM. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Be certain to enter the correct country code for the SKREEM/WCM. If the incorrect country code is programmed into the SKREEM, it cannot be changed and the SKREEM must be replaced. NOTE: In addition, the SKREEM/WCM must be configured for certain optional equipment in the vehicle, including Tire Pressure Monitor (TPM), Remote Keyless Entry (RKE) and Remote Start. Follow the programming steps outlined in the diagnostic scan tool under MISCELLANEOUS FUNCTIONS for the WCM/WIRELESS CONTROL MODULE menu item as appropriate. NOTE: A replacement SKREEM/WCM is supplied with TPM enabled by default; therefore, if the vehicle is not equipped with TPM, the ElectroMechanical Instrument Cluster (EMIC) will incorrectly learn that the vehicle has TPM after the replacement SKREEM is installed. The TPM indicator in the EMIC will illuminate to show a TPM fault condition after TPM has been disabled in the SKREEM. The EMIC must unlearn TPM to correct this false TPM indication. Follow the programming steps outlined in the diagnostic scan tool for CLEAR LEARNED FEATURES under MISCELLANEOUS FUNCTIONS for the INSTRUMENT CLUSTER menu item as appropriate. NOTE: If the PCM/ECM and the SKREEM/WCM are replaced at the same time, all vehicle ignition keys will need to be replaced and the new keys programmed into the new SKREEM/WCM. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 4125 Engine Control Module: Testing and Inspection Programming The SKREEM/WCM Using The Scan Tool STANDARD PROCEDURE - PROGRAMMING THE SKREEM/WCM USING THE SCAN TOOL CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the scan tool. CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal Engine Control Module: Service and Repair Removal 6.7L DIESEL The Engine Control Module (ECM) (5) is located on the left side of the engine. A support bracket mounts to the block with four capscrews and vibration isolators. A ground wire is fastened to the bracket. The other end of the wire is fastened to the engine block. 1. Record any Diagnostic Trouble Codes (DTC's) found in the ECM. To avoid possible voltage spike damage to the ECM, ignition key must be off, and both negative battery cables must be disconnected before unplugging ECM connectors. 2. Disconnect both negative battery cables at both batteries. Access to the ECM is easier by working through the left front wheel opening. 3. Remove left front wheel. 4. Remove plastic left front fender splash shield. 5. Remove electrical connector bolts at ECM. Note: As each bolt is being removed, very carefully remove connectors from the ECM. 6. Remove three ECM mounting bolts (6) and remove ECM from engine. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 4128 Engine Control Module: Service and Repair Installation 6.7L DIESEL Do not apply paint to ECM or a poor ground will result. 1. Position ECM (5) to the ECM support bracket and install mounting bolts. Tighten bolts to 24 Nm (18 ft. lbs.). 2. Check pins in electrical connectors for corrosion, damage or dirt intrusion. Also check all pins for being bent. Repair as necessary. Damaged, dirty, bent or corroded pins could result in poor conductivity, causing intermittent electrical issues or DTC's. 3. Clean pins in electrical connectors with an electrical contact cleaner. 4. Install connectors to ECM. Tighten connector bolts to 3 Nm (27 in. lbs.). 5. Install splash shield. 6. Install left front wheel. 7. Connect both negative battery cables. 8. Use a diagnostic scan tool to erase any Diagnostic Trouble Codes (DTC's) from ECM. FUEL INJECTOR ID CORRECTION CODES: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 4129 Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector (1) and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Engine Control Module (ECM) using a diagnostic scan tool. In addition, if a new ECM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new ECM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4133 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4134 Main Relay (Computer/Fuel System): Diagrams Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4135 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4136 Main Relay (Computer/Fuel System): Testing and Inspection Fig.1 ASD And Fuel Pump Relay Terminals-Type 1 Fig.2 ASD And Fuel Pump Relay Terminals-Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4137 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Diagrams Oxygen Sensor Relay: Diagrams 2007-2009 Ram truck, 6.7L, use an O2 module for oxygen sensor heater control. The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 4145 8w-30-17 Connector C1 pin 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4148 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4149 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4150 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4151 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4152 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4153 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4154 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4155 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4156 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4157 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4158 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4159 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4160 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4161 Fuel Pump Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4162 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4163 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4164 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4165 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4166 Fuel Pump Relay: Connector Views Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 4167 Fuel Pump Relay: Description and Operation The fuel transfer pump (fuel lift pump) is part of the fuel pump module. The fuel pump module is located in the fuel tank. The 12-volt electric pump is operated and controlled by the Engine Control Module (ECM). The ECM controls a relay in the intelligent Power Module (IPM) for transfer pump operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations Intake Air Heater Relay: Locations Component ID: 240 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 FUSED B(+) A19 10DG 30 FUSED B(+) A19 10RD/YL 85 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 86 GROUND Z174 18BK 86 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 87 INTAKE AIR HEATER RELAY OUTPUT A58 4BK Component Location - 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Page 4171 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Page 4172 Intake Air Heater Relay: Diagrams Component ID: 240 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 FUSED B(+) A19 10DG 30 FUSED B(+) A19 10RD/YL 85 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 86 GROUND Z174 18BK 86 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 87 INTAKE AIR HEATER RELAY OUTPUT A58 4BK Component Location - 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Page 4173 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Page 4174 Intake Air Heater Relay: Description and Operation OPERATION The Engine Control Module (ECM) operates the heating element through the intake manifold air heater relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Service and Repair > Removal Intake Air Heater Relay: Service and Repair Removal REMOVAL The intake manifold air heater relay (5) is located in the engine compartment. It attached to a bracket. This bracket is attached to the right battery tray (3). The mounting bracket and relay is replaced as an assembly. 1. Disconnect both negative battery cables at both batteries. 2. Disconnect relay trigger wires (4) at relays. Note position of wiring before removing. 3. Remove nuts (2) at cable connectors and disconnect cables (1) from mounting studs. Note position of cables before removing. 4. Remove two relay mounting bracket screws (6) and remove relay assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Service and Repair > Removal > Page 4177 Intake Air Heater Relay: Service and Repair Installation INSTALLATION The intake manifold air heater relay (5) is located in the engine compartment. It attached to a bracket. This bracket is attached to the right battery tray (3). The mounting bracket and relay is replaced as an assembly. 1. Position relay and install two relay mounting bracket screws (6). 2. Position cables (1) to mounting studs and install nuts (2). 3. Connect relay trigger wires (4) at relays. 4. Connect both negative battery cables to both batteries. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4181 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4182 Main Relay (Computer/Fuel System): Diagrams Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4183 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4184 Main Relay (Computer/Fuel System): Testing and Inspection Fig.1 ASD And Fuel Pump Relay Terminals-Type 1 Fig.2 ASD And Fuel Pump Relay Terminals-Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4185 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4191 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4192 Accelerator Pedal Position Sensor: Diagrams Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4193 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 4196 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) provides the Engine Control Module (ECM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 4199 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4203 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4204 Air Flow Meter/Sensor: Diagrams Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4205 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4206 Air Flow Meter/Sensor: Description and Operation OPERATION The Mass Airflow (MAF) sensor is a frequency based device. A constant voltage is applied to a heated wire on the sensor. This wire is positioned in the air cleaner air stream and is heated by the electrical current that the voltage produces. As air flows across it, it cools down. The heated wire or film is a positive temperature coefficient resistor. This means that its resistance drops when its temperature drops. The drop in resistance allows more current to flow through it in order to maintain the programmed temperature. This current is changed to a frequency which is sent to the Engine Control Module (ECM) and interpreted as air flow. Adjustments for air temperature and humidity are taken into consideration because they also affect the temperature of the heated wire or film. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL The Mass Airflow Sensor (5) is located on the air cleaner cover (8). 1. Disconnect electrical connector (6) at sensor. 2. Remove two mounting screws (4). 3. Remove sensor from air cleaner cover. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 4209 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (4). 4. Install electrical connector (6). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Description and Operation Barometric Pressure Sensor: Description and Operation OPERATION The Inlet Air Temperature/Pressure Sensor is a combination dual-function sensor. The sensor element extends into the intake air stream at the top of the air filter housing. Ambient air temperature as well as barometric pressure is monitored by this sensor. The Engine Control Module (ECM) monitors signals from this sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Service and Repair > Removal Barometric Pressure Sensor: Service and Repair Removal REMOVAL The Inlet Air Temperature/Pressure Sensor (3) is located on the air cleaner cover. 1. Disconnect electrical connector (7) at sensor. 2. Remove mounting screw (2). 3. Remove sensor from air cleaner cover. 4. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Service and Repair > Removal > Page 4215 Barometric Pressure Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor (3) into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (2). 4. Install electrical connector (7). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Component ID: 388 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 BATT TEMP SIGNAL K25 20DB/VT 2 SENSOR GROUND K900 20DB/DG Component Location - 32 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 4219 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 4220 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 4221 Battery Temperature Sensor: Diagrams Component ID: 388 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 BATT TEMP SIGNAL K25 20DB/VT 2 SENSOR GROUND K900 20DB/DG Component Location - 32 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 4222 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 4223 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Description DESCRIPTION The Battery Temperature Sensor (BTS) is used only on the diesel engine. It is attached to the battery tray located under the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description > Page 4226 Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Operation OPERATION The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Removal REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4) . 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3) . 3. Disconnect sensor from engine wire harness electrical connector. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal > Page 4229 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Installation INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4233 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4234 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4235 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4236 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4237 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4238 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4239 Camshaft Position Sensor: Diagrams Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4240 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4241 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4242 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4243 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4244 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4245 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) is located below the fuel injection pump. It is bolted to the back of the timing gear cover. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 4248 Camshaft Position Sensor: Description and Operation Operation 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) contains a hall effect device. A rotating target wheel (tonewheel) for the CMP is located on the front timing gear. This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CMP. When the leading edge of the tonewheel notch passes the tip of the CMP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CMP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The CMP provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses the CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal Camshaft Position Sensor: Service and Repair Removal 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) on the diesel engine is located below the fuel injection pump (1). It is bolted to the back of the timing gear cover. 1. Disconnect electrical connector (5) at CMP sensor. 2. Remove sensor mounting bolt (6). 3. Carefully twist sensor from timing gear cover. 4. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 4251 Camshaft Position Sensor: Service and Repair Installation 5.9L/6.7L DIESEL The CMP (1) is located on the back of the timing gear cover. 1. Clean out machined hole in back of timing gear cover. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into timing gear cover with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to back of timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in.lbs.). 5. Connect electrical connector to sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Description Coolant Temperature Sensor/Switch (For Computer): Description and Operation Description DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Description > Page 4256 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Operation OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air-fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: - for engine coolant temperature gauge operation through CAN Bus communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid on/off times - Cooling fan control - Temperature gauge operation - A/C cutoff at high coolant temperatures - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Removal Coolant Temperature Sensor/Switch (For Computer): Service and Repair Removal 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL WARNING: Hot, pressurized coolant can cause injury by scalding. Cooling system must be partially drained before removing the coolant temperature sensor. 1. Partially drain the cooling system. ECT LOCATION - 5.9L DIESEL 2. Remove heat shield (if equipped). 3. Disconnect the electrical connector (2) from the ETC sensor (3). 4. Remove the ETC sensor from the cylinder head. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Removal > Page 4259 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Installation 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL 1. Install sensor (1 or 3) to engine. 2. Tighten sensor to 18 Nm (13 ft. lbs.) torque. ECT LOCATION - 5.9L DIESEL 3. Connect electrical connector (2) to ETC sensor (1 or 3). 4. Install heat shield (if equipped). 5. Replace any lost engine coolant. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4263 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4264 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4265 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4266 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4267 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4268 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4269 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4270 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4271 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4272 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4273 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4274 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4275 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4276 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4277 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4278 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4279 Crankshaft Position Sensor: Diagrams Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4280 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4281 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4282 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4283 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4284 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4285 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4286 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4287 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4288 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4289 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4290 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4291 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4292 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4293 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4294 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4295 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The Crankshaft Position Sensor (CKP) on the diesel engine is attached at the front / left side of the engine next to the engine harmonic balancer (crankshaft damper). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 4298 Crankshaft Position Sensor: Description and Operation Operation OPERATION The Crankshaft Position Sensor (CKP) (5) is the primary engine speed indicator for the engine after the engine is running. The CKP contains a hall effect device. A rotating, notched target wheel (tonewheel) (3) for the CKP is attached to the engine harmonic balancer (2). This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CKP. When the leading edge of the tonewheel notch passes the tip of the CKP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CKP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The Camshaft Position Sensor (CMP) also provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses this CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal Crankshaft Position Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle 2. Disconnect electrical connector (4) at CKP sensor. 3. Remove 1 sensor mounting bolt (3). 4. Remove CKP sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 4301 Crankshaft Position Sensor: Service and Repair Installation INSTALLATION 1. Position and install CKP sensor (5) to engine. 2. Install 1 sensor mounting bolt and tighten to 9 Nm (80 in. lbs.) torque. 3. Install electrical connector (4) to CKP sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations Crankcase Pressure Sensor: Locations Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 4305 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 4306 Crankcase Pressure Sensor: Diagrams Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 4307 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 4308 Crankcase Pressure Sensor: Description and Operation OPERATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). The CP sensor monitors crankcase pressure that builds up as the result of combustion gas blow-by. The Engine Control Module (ECM) uses data from the CP sensor to determine the condition of the crankcase breather (ventilation) filter. The ECM can also determine if a crankcase breather (ventilation) filter is present. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal Crankcase Pressure Sensor: Service and Repair Removal REMOVAL The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Remove mounting screw (6). 2. Disconnect electrical connector (7). 3. Remove sensor (5) from valve cover (4). 4. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal > Page 4311 Crankcase Pressure Sensor: Service and Repair Installation INSTALLATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Check condition of sensor O-ring. 2. Install sensor (5) into valve cover (4). 3. Install mounting screw (6). Tighten to 3 Nm (27 in. lbs.) torque. 4. Connect electrical connector (7). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4316 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4317 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4318 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4319 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4320 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4321 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4322 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4323 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4326 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4327 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4328 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4329 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4330 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4331 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4332 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4333 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 4336 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 4339 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 4344 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 4345 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 4346 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 4347 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 4348 Component Location - 25 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 4349 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 4352 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 4353 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 4354 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 4355 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 4356 Component Location - 25 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 4357 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation DESCRIPTION The fuel tank module is installed in the top of the fuel tank. The fuel tank module contains the following components: - An electric fuel transfer (lift) pump - Fuel reservoir - A separate in-tank fuel filter - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection - A special lockring to retain module to fuel tank - Fuel return line connection. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Removal Fuel Level Sensor: Service and Repair Removal REMOVAL 1. Drain and remove fuel tank. 2. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose. 3. Position Special Tool 9340 (3) into notches on outside edge of lockring (5). 4. Install 1/2 inch drive breaker bar (1) to tool 9340 (3). 5. Rotate breaker bar counterclockwise to remove lockring. 6. Remove lockring. The module will spring up slightly when lockring is removed. 7. Remove module from fuel tank. Be careful not to bend float arm while removing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Removal > Page 4363 Fuel Level Sensor: Service and Repair Installation INSTALLATION CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced. 1. Using a new seal (gasket), position fuel pump module into opening in fuel tank. 2. Position lockring (5) over top of fuel pump module. 3. Rotate module until embossed alignment arrow points to center alignment mark. This step must be performed to prevent float from contacting side of fuel tank. Also be sure fuel fitting on top of pump module is pointed to drivers side of vehicle. 4. Install Special Tool 9340 (3) to lockring. 5. Install 1/2 inch drive breaker (1) into Special Tool 9340 (3). 6. Tighten lockring (clockwise) until all seven notches have engaged. 7. Install fuel tank. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Locations High Idle Switch: Locations Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 4367 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 4368 High Idle Switch: Diagrams Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 4369 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations Intake Air Temperature Sensor: Component Locations Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4374 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4375 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4376 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4377 Component Location - 4 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4378 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4379 Cab/Chassis Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. Pick Up Models Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4380 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4381 Intake Air Temperature Sensor: Connector Locations Component ID: 406 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (6.7L DH) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4382 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4383 Component Location - 7 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4384 Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 IAT SIGNAL K21 20DB/LG 2 SENSOR GROUND K900 20DB/DG Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4385 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4386 Component Location - 7 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4387 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor Intake Air Temperature Sensor: Diagrams Intake Air Temperature Sensor Component ID: 406 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (6.7L DH) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4390 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4391 Component Location - 7 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4392 Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 IAT SIGNAL K21 20DB/LG 2 SENSOR GROUND K900 20DB/DG Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4393 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4394 Component Location - 7 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4395 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4396 Intake Air Temperature Sensor: Diagrams Sensor-Temperature/Pressure-MAP Component ID: 427 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A SENSOR GROUND K210 18DB/TN B INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG C 5 VOLT SUPPLY F855 18PK/YL D BOOST PRESSURE SENSOR SIGNAL K37 18LB Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4397 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 BOOST PRESSURE SENSOR SIGNAL K37 18BR 2 5 VOLT SUPPLY F855 18PK/YL 3 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 3 CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR K735 18BR/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4398 4 SENSOR GROUND K916 18BR/OR Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4399 Intake Air Temperature Sensor: Diagrams Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4400 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4401 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4402 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4403 Component Location - 4 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4404 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4405 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Sensor-Temperature/Pressure-Intake Intake Air Temperature Sensor: Description and Operation Sensor-Temperature/Pressure-Intake OPERATION The Inlet Air Temperature/Pressure Sensor is a combination dual-function sensor. The sensor element extends into the intake air stream at the top of the air filter housing. Ambient air temperature as well as barometric pressure is monitored by this sensor. The Engine Control Module (ECM) monitors signals from this sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Sensor-Temperature/Pressure-Intake > Page 4408 Intake Air Temperature Sensor: Description and Operation Sensor-Temperature/Pressure-MAP OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet Intake Air Temperature Sensor: Service and Repair Sensor-Temperature/Pressure-Inlet Removal REMOVAL The Inlet Air Temperature/Pressure Sensor (3) is located on the air cleaner cover. 1. Disconnect electrical connector (7) at sensor. 2. Remove mounting screw (2). 3. Remove sensor from air cleaner cover. 4. Check condition of sensor O-ring. Installation INSTALLATION 1. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 4411 2. Position sensor (3) into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (2). 4. Install electrical connector (7). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 4412 Intake Air Temperature Sensor: Service and Repair Sensor-Temperature/Pressure-MAP Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Pick Up Models REMOVAL-PICK UP MODELS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 4413 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 4414 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Description Knock Sensor: Description and Operation Description DESCRIPTION Two knock sensors are bolted into the cylinder block under the intake manifold 3.7L, 4.7L & 8.3L. Two knock sensors are also used with the 5.7L. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Description > Page 4419 Knock Sensor: Description and Operation Operation OPERATION Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure Manifold Pressure/Vacuum Sensor: Locations Sensor-Manifold Absolute Pressure Component ID: 411 Component : SENSOR-MANIFOLD ABSOLUTE PRESSURE Connector: Name : SENSOR-MANIFOLD ABSOLUTE PRESSURE Color : GRAY # of pins : 3 Qualifier : (NGC) Pin Description Circuit 1 MAP SIGNAL K1 20VT/BR 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 4424 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 4425 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 4426 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 4427 Manifold Pressure/Vacuum Sensor: Locations Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 4428 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 4429 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 4430 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 4431 Component Location - 4 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 4432 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 4433 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 4434 Manifold Pressure/Vacuum Sensor: Locations Sensor-Temperature/Pressure-MAP Pick Up Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). Cab/Chassis Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Manifold Absolute Pressure Component ID: 411 Component : SENSOR-MANIFOLD ABSOLUTE PRESSURE Connector: Name : SENSOR-MANIFOLD ABSOLUTE PRESSURE Color : GRAY # of pins : 3 Qualifier : (NGC) Pin Description Circuit 1 MAP SIGNAL K1 20VT/BR 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 4437 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 4438 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 4439 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 4440 Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 4441 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 4442 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 4443 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 4444 Component Location - 4 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 4445 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 4446 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 4447 Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Temperature/Pressure-MAP Component ID: 427 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A SENSOR GROUND K210 18DB/TN B INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG C 5 VOLT SUPPLY F855 18PK/YL D BOOST PRESSURE SENSOR SIGNAL K37 18LB Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 4448 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 BOOST PRESSURE SENSOR SIGNAL K37 18BR 2 5 VOLT SUPPLY F855 18PK/YL 3 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 3 CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR K735 18BR/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 4449 4 SENSOR GROUND K916 18BR/OR Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Sensor-MAP Manifold Pressure/Vacuum Sensor: Description and Operation Sensor-MAP DESCRIPTION A combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is used. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Sensor-MAP > Page 4452 Manifold Pressure/Vacuum Sensor: Description and Operation Sensor-Temperature/Pressure-MAP OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Removal-Pick Up Models REMOVAL-PICK UP MODELS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 4455 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 4456 Manifold Pressure/Vacuum Sensor: Service and Repair Installation Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 4457 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4462 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4463 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4464 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4465 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4466 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4467 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4468 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4469 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4470 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4471 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4472 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4473 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4474 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4475 Oil Pressure Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4476 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4477 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4478 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4479 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4488 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4489 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4490 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4491 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4492 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4493 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4494 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4500 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4501 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4502 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 08-035-08 > Nov > 08 > Engine Controls - Oxygen Sensor Testing Information Oxygen Sensor: All Technical Service Bulletins Engine Controls - Oxygen Sensor Testing Information NUMBER: 08-035-08 GROUP: Electrical DATE: November 21, 2008 SUBJECT: Proper Testing Tools For Oxygen Sensor Terminals OVERVIEW: This bulletin describes the use of proper test probes to test the Oxygen (02) Sensor connector terminals equipped with the new TP2 style of sensor. MODELS: 2007-2009 (DH) 2500 Pick Up 2007-2009 (D1) 3500 Pick Up NOTE: This bulletin applies to models equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: The new TP2 style 02 sensors have smaller terminals that may be damaged (spread) when using standard Digital Volt Ohm Meter (DVOM) test probes. The recommended tool for these testing procedures is the Miller Tool # 6801 (Fig. 1) Two (2) of these probes are required when performing circuit tests as described in DealerCONNECT. The tool was originally included as part of Miller Tool # 6807 and # 8197A. Each of these kits contained one (1) # 6801 terminal probe. Two (2) additional Miller test probes # 6801 will be delivered to affected Dodge dealers shortly. Two (2) new terminal probes (# 6801) will be included and shipped as kit # 10190. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4512 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4513 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4514 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4519 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4520 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4521 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4522 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4523 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4524 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4525 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 08-035-08 > Nov > 08 > Engine Controls - Oxygen Sensor Testing Information Oxygen Sensor: All Technical Service Bulletins Engine Controls - Oxygen Sensor Testing Information NUMBER: 08-035-08 GROUP: Electrical DATE: November 21, 2008 SUBJECT: Proper Testing Tools For Oxygen Sensor Terminals OVERVIEW: This bulletin describes the use of proper test probes to test the Oxygen (02) Sensor connector terminals equipped with the new TP2 style of sensor. MODELS: 2007-2009 (DH) 2500 Pick Up 2007-2009 (D1) 3500 Pick Up NOTE: This bulletin applies to models equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: The new TP2 style 02 sensors have smaller terminals that may be damaged (spread) when using standard Digital Volt Ohm Meter (DVOM) test probes. The recommended tool for these testing procedures is the Miller Tool # 6801 (Fig. 1) Two (2) of these probes are required when performing circuit tests as described in DealerCONNECT. The tool was originally included as part of Miller Tool # 6807 and # 8197A. Each of these kits contained one (1) # 6801 terminal probe. Two (2) additional Miller test probes # 6801 will be delivered to affected Dodge dealers shortly. Two (2) new terminal probes (# 6801) will be included and shipped as kit # 10190. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4535 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4536 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4537 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4547 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4548 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4549 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4550 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4551 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4552 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4553 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen Oxygen Sensor: Locations Sensor - Oxygen The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4556 Oxygen Sensor: Locations Sensor - Oxygen 1/1 Component ID: 416 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : BLACK # of pins : 4 Qualifier : (3.7L/5.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4557 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4558 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4559 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4560 Connector: Name : SENSOR-OXYGEN 1/1 Color : GRAY # of pins : 4 Qualifier : (4.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4561 Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4562 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4563 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4564 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4565 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4566 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4567 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4568 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4569 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4570 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4571 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4572 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4573 Oxygen Sensor: Locations Sensor - Oxygen 1/2 Component ID: 417 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 4 Qualifier : (3.7L/5.7L LD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4574 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4575 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4576 Connector: Name : SENSOR-OXYGEN 1/2 Color : GRAY # of pins : 4 Qualifier : (4.7L/5.7L HD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4577 Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4578 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4579 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4580 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4581 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4582 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4583 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4584 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 4585 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor Oxygen Sensor: Diagrams Module-O2 Sensor Component ID: 207 Component : MODULE-O2 SENSOR Connector: Name : MODULE-O2 SENSOR Color : # of pins : 16 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 3 DIAGNOSTIC PORT LOW DATA LINK D132 20WT 4 O2 1/2 SIGNAL K141 20DB/YL 5 02 1/2 PUMP CURRENT K734 20BR/DG 6 O2 1/1 SIGNAL K41 20DB/LB 7 02 1/1 PUMP CURRENT K89 20BR/LG 8 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 9 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 10 GROUND Z902 20BK 11 DIAGNOSTIC PORT HIGH DATA LINK D133 20WT/OR 12 O2 1/2 RETURN K904 20DB/DG 13 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 14 O2 1/1 RETURN K902 20BR/DG 15 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 16 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB Connector: Name : MODULE-O2 SENSOR Color : # of pins : 16 Qualifier : (6.7L DIESEL) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4588 Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 3 DIAGNOSTIC PORT LOW DATA LINK D132 20WT 4 O2 1/2 SIGNAL K141 20DB/YL 5 02 1/2 PUMP CURRENT K734 20BR/DG 6 O2 1/1 SIGNAL K41 20DB/LB 7 02 1/1 PUMP CURRENT K89 20BR/LG 8 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 9 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 10 GROUND Z902 20BK 11 DIAGNOSTIC PORT HIGH DATA LINK D133 20WT/OR 12 O2 1/2 RETURN K904 20DB/DG 13 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 14 O2 1/1 RETURN K902 20BR/DG 15 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 16 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4589 Oxygen Sensor: Diagrams Sensor-Oxygen 1/1 Component ID: 416 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : BLACK # of pins : 4 Qualifier : (3.7L/5.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4590 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4591 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4592 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4593 Connector: Name : SENSOR-OXYGEN 1/1 Color : GRAY # of pins : 4 Qualifier : (4.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4594 Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4595 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4596 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4597 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4598 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4599 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4600 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4601 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4602 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4603 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4604 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4605 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4606 Oxygen Sensor: Diagrams Sensor-Oxygen 1/2 Component ID: 417 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 4 Qualifier : (3.7L/5.7L LD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4607 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4608 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4609 Connector: Name : SENSOR-OXYGEN 1/2 Color : GRAY # of pins : 4 Qualifier : (4.7L/5.7L HD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4610 Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4611 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4612 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4613 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4614 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4615 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4616 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4617 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4618 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models Oxygen Sensor: Description and Operation Description - Pick Up Models DESCRIPTION - PICK UP MODELS The two oxygen (O2) sensors (1) and (2) are located at each end of the #2 catalyst. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models > Page 4621 Oxygen Sensor: Description and Operation Operation - Pick Up Models OPERATION - PICK UP MODELS Two different six-wire O2 sensors are used. These sensors are titled 1/1 upstream (1), and 1/2 downstream (2). A separate O2 Sensor Module (1) is also used. The engine aftertreatment system monitors the O2 content in the diesel engine exhaust. The ECM monitors the exhaust gases for oxygen content and varies the rich/lean fuel mixture of the intake air fuel mixture to adjust the system. This diagnostic monitors the status message broadcast by the O2 Sensor Module (1) for the upstream O2 sensor's internal heater circuit. The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the O2 Sensor Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models > Page 4622 Oxygen Sensor: Description and Operation Oxygen Sensor Module Description - Pick Up Models DESCRIPTION - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). Operation - Pick Up Models OPERATION - PICK UP MODELS Two different six-wire O2 sensors are used. These sensors are titled 1/1 upstream, and 1/2 downstream. A separate O2 Sensor Module (1) is also used. The engine aftertreatment system monitors the O2 content in the diesel engine exhaust. The ECM monitors the exhaust gases for oxygen content and varies the rich/lean fuel mixture of the intake air fuel mixture to adjust the system. This diagnostic monitors the status message broadcast by the O2 Sensor Module (1) for the upstream O2 sensor's internal heater circuit. The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the O2 Sensor Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module Oxygen Sensor: Service and Repair Oxygen Sensor Module Removal - Pick Up Models REMOVAL - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). 1. Raise and support vehicle. 2. Disconnect electrical connector (2) at module (1). 3. Remove four bolts (3). 4. Remove module from frame rail. Installation - Pick Up Models INSTALLATION - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). 1. Position module (1) to frame rail (4). 2. Install four bolts (3). 3. Tighten bolts (3) to 6 Nm (53 in. lbs.) torque. 4. Connect electrical connector (2) to module (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 4625 5. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 4626 Oxygen Sensor: Service and Repair Removal REMOVAL - PICK UP MODELS The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: The exhaust manifold, exhaust pipes and catalytic converters become very hot during engine operation. Allow engine to cool before removing oxygen sensor. 1. Raise and support vehicle. 2. Disconnect main wire connector from O2S sensor pigtail harness. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove O2S sensor with an oxygen sensor removal and installation tool. 4. Clean threads in catalytic convertor using appropriate tap. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 4627 Oxygen Sensor: Service and Repair Installation INSTALLATION - PICK UP MODELS The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. Threads of NEW oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. Be careful not to get anti-seize compound on sensor tip. 1. Install O2S sensor. Tighten to 41 Nm (30 ft. lbs.) torque. 2. Connect O2S sensor pigtail harness to main wire harness connector. 3. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Description Power Steering Pressure Switch: Description and Operation Description DESCRIPTION A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will only be used on HD vehicles with the 5.7L engines. There is no pressure switch used for the 3.7L, 4.7L, 5.9LDiesel engine or the 5.7L LD vehicle pump. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Description > Page 4632 Power Steering Pressure Switch: Description and Operation Operation OPERATION The switch is used on the 5.7L V-8 engines HD vehicles only. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal Pressure Feedback Exhaust Sensor: Service and Repair Removal REMOVAL 1. Disconnect exhaust gas pressure sensor electrical connector (1). 2. Using a 6 point deepwell socket, remove exhaust gas sensor (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal > Page 4637 Pressure Feedback Exhaust Sensor: Service and Repair Installation INSTALLATION 1. Using a 6 point deepwell socket, install exhaust gas pressure sensor. 2. Tighten sensor to 18 Nm (13 ft. lbs.). 3. Connect exhaust gas pressure sensor electrical connector (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4642 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4643 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4644 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4645 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4646 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4647 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4648 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4649 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4650 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4651 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4652 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4655 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4656 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4657 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4658 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4659 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4660 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4661 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4662 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4663 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4664 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4665 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 4668 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 4669 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 4670 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 4671 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 4672 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 4675 TRS REMOVAL/INSTALLATION 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 4676 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 4677 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 4678 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 4679 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations Turbocharger Speed Sensor: Locations Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations > Page 4683 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations > Page 4684 Turbocharger Speed Sensor: Diagrams Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations > Page 4685 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4690 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4691 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4692 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4693 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4694 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4695 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4696 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4697 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4698 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4699 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4700 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4701 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4702 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4703 Vehicle Speed Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4704 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4705 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4706 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4707 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4713 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4714 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4715 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4716 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4717 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4718 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4719 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4720 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4723 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4724 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4725 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4726 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4727 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4728 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4729 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4730 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 4733 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 4736 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations Crankcase Pressure Sensor: Locations Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 4740 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 4741 Crankcase Pressure Sensor: Diagrams Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 4742 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 4743 Crankcase Pressure Sensor: Description and Operation OPERATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). The CP sensor monitors crankcase pressure that builds up as the result of combustion gas blow-by. The Engine Control Module (ECM) uses data from the CP sensor to determine the condition of the crankcase breather (ventilation) filter. The ECM can also determine if a crankcase breather (ventilation) filter is present. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal Crankcase Pressure Sensor: Service and Repair Removal REMOVAL The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Remove mounting screw (6). 2. Disconnect electrical connector (7). 3. Remove sensor (5) from valve cover (4). 4. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal > Page 4746 Crankcase Pressure Sensor: Service and Repair Installation INSTALLATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Check condition of sensor O-ring. 2. Install sensor (5) into valve cover (4). 3. Install mounting screw (6). Tighten to 3 Nm (27 in. lbs.) torque. 4. Connect electrical connector (7). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Diagrams EGR Temperature Sensor: Diagrams Component ID: 394 Component : SENSOR-EGR TEMPERATURE Connector: Name : SENSOR-EGR TEMPERATURE Color : # of pins : 2 Qualifier : (6.7L DC) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 EGR TEMPERATURE SENSOR SIGNAL K935 18DB Connector: Name : SENSOR-EGR TEMPERATURE Color : # of pins : 2 Qualifier : (6.7L DH/D1) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 EGR TEMPERATURE SENSOR SIGNAL K935 18DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Description and Operation > Operation-Cab/Chassis Models EGR Temperature Sensor: Description and Operation Operation-Cab/Chassis Models OPERATION-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near the EGR valve. The EGR temperature sensor is a negative temperature coefficient thermistor used to measure the temperature of the EGR gas flow after it exits the EGR cooler. The ECM (Engine Control Module) supplies 5-volts to the EGR temperature signal circuit. To determine the temperature of the EGR gas flow, the ECM monitors the change in voltage caused by changes in the resistance of the sensor. The ECM uses the exhaust gas recirculation temperature value for the engine protection system, and also for engine emissions control. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Description and Operation > Operation-Cab/Chassis Models > Page 4752 EGR Temperature Sensor: Description and Operation Operation-Pick Up Models OPERATION-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). A temperature probe (1) is located at the end of the sensor assembly (3). The EGR temperature sensor is a negative temperature coefficient thermistor used to measure the temperature of the EGR gas flow after it exits the EGR cooler. The ECM (Engine Control Module) supplies 5-volts to the EGR temperature signal circuit. To determine the temperature of the EGR gas flow, the ECM monitors the change in voltage caused by changes in the resistance of the sensor. The ECM uses the exhaust gas recirculation temperature value for the engine protection system, and also for engine emissions control. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal EGR Temperature Sensor: Service and Repair Removal Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near EGR valve. 1. Disconnect electrical connector (2) at sensor. 2. Remove sensor (1) from EGR tube (6). Removal-Pick Up Models REMOVAL-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 4755 1. If equipped, remove four cover bolts (2) and remove EGR crossover tube cover (1). 2. If equipped, remove EGR valve cover (2). 3. A pigtail wiring harness connects sensor to engine wiring harness. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 4756 4. Unscrew nut (2) at intake manifold. 5. Disconnect sensor pigtail harness electrical connector from engine wiring harness and remove sensor assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 4757 EGR Temperature Sensor: Service and Repair Installation Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near the EGR valve. 1. Clean EGR crossover tube at sensor mounting point. 2. Check condition of the sensors metal gasket and replace if necessary. 3. Install sensor (1) to EGR tube (6). Tighten to 18 Nm (13 ft. lbs.). 4. Connect electrical connector (2) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 4758 1. A pigtail wiring harness (3) connects the sensor to the engine wiring harness. 2. Position sensor probe (1) into intake manifold. 3. Screw and tighten nut (2) into intake manifold. 4. Connect electrical connector (4) to engine wiring harness. 5. Install EGR valve cover (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 4759 6. Install EGR crossover tube cover (1) and four cover bolts (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Description and Operation Exhaust Pressure Differential Sensor: Description and Operation DESCRIPTION The Exhaust Differential Pressure Sensor is remotely mounted on the transmission housing. Two pressure tubes measure pressure before and after the Diesel Particulate Filter (DPF)/Diesel Oxidation Catalyst (DOC). The sensor is critical for fail-safe of regeneration strategy, because it interprets high pressure drops as possible high soot loads. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Differential Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect electrical connector. 3. Disconnect hoses at pressure differential pressure sensor. 4. Remove mounting bolt and differential pressure sensor. 5. Remove mounting bolts (1). 6. Remove pressure differential pressure tubing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal > Page 4765 Exhaust Pressure Differential Sensor: Service and Repair Installation INSTALLATION 1. Install differential pressure tubing, if removed. Tighten fittings to 30 Nm (22 ft. lbs.). 2. Position differential pressure sensor (1). 3. Install mounting nuts (5) and bolts. Tighten to 10 Nm (89 in. lbs.). 4. Install hose (2) to the rear DPF tubing. 5. Install hose (3) to the front DPF tubing. 6. Connect electrical connector (6). 7. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal Pressure Feedback Exhaust Sensor: Service and Repair Removal REMOVAL 1. Disconnect exhaust gas pressure sensor electrical connector (1). 2. Using a 6 point deepwell socket, remove exhaust gas sensor (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal > Page 4770 Pressure Feedback Exhaust Sensor: Service and Repair Installation INSTALLATION 1. Using a 6 point deepwell socket, install exhaust gas pressure sensor. 2. Tighten sensor to 18 Nm (13 ft. lbs.). 3. Connect exhaust gas pressure sensor electrical connector (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4775 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4776 Accelerator Pedal Position Sensor: Diagrams Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4777 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 4780 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) provides the Engine Control Module (ECM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 4783 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4787 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4788 Air Flow Meter/Sensor: Diagrams Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4789 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4790 Air Flow Meter/Sensor: Description and Operation OPERATION The Mass Airflow (MAF) sensor is a frequency based device. A constant voltage is applied to a heated wire on the sensor. This wire is positioned in the air cleaner air stream and is heated by the electrical current that the voltage produces. As air flows across it, it cools down. The heated wire or film is a positive temperature coefficient resistor. This means that its resistance drops when its temperature drops. The drop in resistance allows more current to flow through it in order to maintain the programmed temperature. This current is changed to a frequency which is sent to the Engine Control Module (ECM) and interpreted as air flow. Adjustments for air temperature and humidity are taken into consideration because they also affect the temperature of the heated wire or film. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL The Mass Airflow Sensor (5) is located on the air cleaner cover (8). 1. Disconnect electrical connector (6) at sensor. 2. Remove two mounting screws (4). 3. Remove sensor from air cleaner cover. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 4793 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (4). 4. Install electrical connector (6). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure Fuel Pressure Sensor/Switch: Locations Sensor-Fuel Rail Pressure Component ID: 404 Component : SENSOR-FUEL RAIL PRESSURE Connector: Name : SENSOR-FUEL RAIL PRESSURE Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL RAIL SENSOR RETURN K915 18BR/WT Pin Description Circuit 1 SENSOR GROUND K916 18BR/OR 2 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 3 5 VOLT SUPPLY F855 18PK/YL Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure > Page 4798 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure > Page 4799 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure > Page 4800 Fuel Pressure Sensor/Switch: Locations Sensor-Fuel Pressure The fuel pressure sensor (1) is mounted to the rear of the fuel rail (6). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 4801 Fuel Pressure Sensor/Switch: Diagrams Component ID: 404 Component : SENSOR-FUEL RAIL PRESSURE Connector: Name : SENSOR-FUEL RAIL PRESSURE Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL RAIL SENSOR RETURN K915 18BR/WT Pin Description Circuit 1 SENSOR GROUND K916 18BR/OR 2 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 3 5 VOLT SUPPLY F855 18PK/YL Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 4802 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 4803 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 4804 Fuel Pressure Sensor/Switch: Description and Operation OPERATION The fuel pressure sensor monitors actual high-pressure within the fuel rail. An output signal from this sensor (relating to fuel pressure) is sent to the Engine Control Module (ECM). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal Fuel Pressure Sensor/Switch: Service and Repair Removal REMOVAL The fuel pressure sensor (1) is mounted to the rear of the fuel rail (6). 1. Remove two bolts (3) and bracket (4) at rear of cylinder head. 2. Remove engine oil dipstick tube mounting bolts. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal > Page 4807 3. Disconnect electrical connector (2) at sensor. 4. Remove sensor (1) from fuel rail. 5. Inspect sensor sealing surface. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal > Page 4808 Fuel Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Inspect fuel pressure sensor sealing surface. 2. Lubricate sensor threads with clean diesel fuel. 3. Install sensor (1) into fuel rail. 4. To prevent leaks, sensor must be tightened to 70 Nm (52 ft. lbs.). 5. Connect electrical connector (2) to sensor. 6. Install rear engine lift bracket (4) and bolts (3). Tighten to 77 Nm (57 ft. lbs.). 7. Install engine oil dipstick tube mounting bolts. 8. Start engine and check for fuel leaks. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations High Idle Switch: Locations Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 4812 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 4813 High Idle Switch: Diagrams Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 4814 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Pick Up Models Turbo Boost Sensor: Locations Pick Up Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Pick Up Models > Page 4819 Turbo Boost Sensor: Locations Cab/Chassis Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Page 4820 Turbo Boost Sensor: Description and Operation OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP Turbo Boost Sensor: Service and Repair Sensor-Temperature/Pressure-MAP Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Removal-Pick Up Models REMOVAL-PICK UP MODELS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP > Page 4823 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP > Page 4824 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP > Page 4825 Turbo Boost Sensor: Service and Repair Sensor-Turbocharger Speed Removal REMOVAL 1. Disconnect negative battery cable. 2. Disconnect speed sensor electrical connector. 3. Remove turbocharger speed sensor mounting bolt (1). 4. Remove turbocharger speed sensor (2). Installation INSTALLATION 1. Install turbocharger speed sensor. 2. Install turbocharger speed sensor mounting bolt. 3. Tighten bolt to 10 Nm (89 in. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Speed Sensor > Component Information > Locations Turbocharger Speed Sensor: Locations Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Speed Sensor > Component Information > Locations > Page 4829 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Speed Sensor > Component Information > Locations > Page 4830 Turbocharger Speed Sensor: Diagrams Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Speed Sensor > Component Information > Locations > Page 4831 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4836 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4837 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4838 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4839 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4840 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4841 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4842 Camshaft Position Sensor: Diagrams Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4843 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4844 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4845 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4846 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4847 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4848 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) is located below the fuel injection pump. It is bolted to the back of the timing gear cover. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 4851 Camshaft Position Sensor: Description and Operation Operation 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) contains a hall effect device. A rotating target wheel (tonewheel) for the CMP is located on the front timing gear. This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CMP. When the leading edge of the tonewheel notch passes the tip of the CMP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CMP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The CMP provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses the CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal Camshaft Position Sensor: Service and Repair Removal 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) on the diesel engine is located below the fuel injection pump (1). It is bolted to the back of the timing gear cover. 1. Disconnect electrical connector (5) at CMP sensor. 2. Remove sensor mounting bolt (6). 3. Carefully twist sensor from timing gear cover. 4. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 4854 Camshaft Position Sensor: Service and Repair Installation 5.9L/6.7L DIESEL The CMP (1) is located on the back of the timing gear cover. 1. Clean out machined hole in back of timing gear cover. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into timing gear cover with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to back of timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in.lbs.). 5. Connect electrical connector to sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4858 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4859 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4860 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4861 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4862 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4863 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4864 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4865 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4866 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4867 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4868 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4869 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4870 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4871 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4872 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4873 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4874 Crankshaft Position Sensor: Diagrams Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4875 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4876 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4877 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4878 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4879 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4880 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4881 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4882 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4883 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4884 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4885 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4886 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4887 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4888 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4889 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4890 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The Crankshaft Position Sensor (CKP) on the diesel engine is attached at the front / left side of the engine next to the engine harmonic balancer (crankshaft damper). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 4893 Crankshaft Position Sensor: Description and Operation Operation OPERATION The Crankshaft Position Sensor (CKP) (5) is the primary engine speed indicator for the engine after the engine is running. The CKP contains a hall effect device. A rotating, notched target wheel (tonewheel) (3) for the CKP is attached to the engine harmonic balancer (2). This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CKP. When the leading edge of the tonewheel notch passes the tip of the CKP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CKP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The Camshaft Position Sensor (CMP) also provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses this CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal Crankshaft Position Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle 2. Disconnect electrical connector (4) at CKP sensor. 3. Remove 1 sensor mounting bolt (3). 4. Remove CKP sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 4896 Crankshaft Position Sensor: Service and Repair Installation INSTALLATION 1. Position and install CKP sensor (5) to engine. 2. Install 1 sensor mounting bolt and tighten to 9 Nm (80 in. lbs.) torque. 3. Install electrical connector (4) to CKP sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal Ignition Switch Lock Cylinder: Service and Repair Removal REMOVAL The ignition key must be in the key cylinder (1) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at the underside of the key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal > Page 4902 Ignition Switch Lock Cylinder: Service and Repair Installation INSTALLATION The ignition key must be in the key cylinder (3) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (3) with the ignition switch (1). 2. Push the key cylinder (3) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Description Knock Sensor: Description and Operation Description DESCRIPTION Two knock sensors are bolted into the cylinder block under the intake manifold 3.7L, 4.7L & 8.3L. Two knock sensors are also used with the 5.7L. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Description > Page 4907 Knock Sensor: Description and Operation Operation OPERATION Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL PRESSURES Fuel Pump/Gear Pump (low pressure) ................................................................................................................................ 551.5 - 1241 KPA (80 - 180 psi) Injection Pump ..................................................................................................................................... ............................ 200 - 1800 bar (2900 - 26107 psi) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test Fuel Pressure: Testing and Inspection Fuel Pump Return Flow Test *FUEL PUMP RETURN FLOW TEST 1. FUEL PUMP RETURN FLOW TEST Using the scan tool, idle the engine and measure the rail pressure and determine if the rail pressure is excessive (above 185,00 kpa/26,831 psi). If it is, troubleshoot for excessive rail pressure first. Remove the banjo bolt from the pressure-limiting valve on the fuel rail. Install fuel system test fitting 9013 into the pressure-limiting valve. Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose into a container Perform the tests listed below to determine if the pressure-limiting valve is leaking. a. Operate the engine at idle and watch for fuel flow into the fuel container. b. Operate the engine at idle and actuate the high pressure safety valve test with the scan tool. Watch for fuel flow into the fuel container. If fuel flows into the fuel container, replace the pressure-limiting valve. If fuel does not leak from the pressure-limiting valve, the test is complete. NOTE: Do not drive the vehicle with any portion of this test kit installed Operate the engine until the engine is at operating temperature. Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing Install fuel system test fitting 9012 in place of the banjo connector. Install a piece of fuel line onto the test fitting and put the open end into the graduated cylinder . Start the engine and let it idle for one minute. Measure the amount of fuel in the graduated cylinder. If the flow is less than 1000ml/minute at idle, the test has successfully passed. If the flow is greater than 1000ml/minute at idle, replace the fuel injection pump. Retest to confirm repair. View Repair Repair - Test Complete. - Perform POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 4914 Fuel Pressure: Testing and Inspection High Pressure Fuel Pump Performance Test *HIGH PRESSURE FUEL PUMP PERFORMANCE TEST If the engine will run do the following: 1. Monitor rail pressure with scan tool while the engine is at idle. 2. Compare the fuel pressure set point with the actual fuel pressure reading. 3. If actual fuel pressure reading fluctuates more than ± 500 psi from the set point, then replace the Fuel Control Actuator (FCA). NOTE: After the actuator is removed, check for debris or corrosion on the FCA. If debris or corrosion is found, replace the entire Fuel Injection Pump. 4. Turn off engine. 5. Disconnect the FCA harness 6. Disconnect high pressure fuel line from fuel rail and route the high pressure fuel line into a graduated cylinder. 7. Crank the engine until fuel exits this line. This will not be high pressure fuel. 8. Crank the engine for three (3) 10 second intervals (Note: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter). Fuel flow specification s based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL If the engine is a no start do the following: 1. Remove fuel pump to rail high pressure fuel line. 2. Inspect the fuel pump outlet port for rust, debris, or other signs of contamination. 3. Replace pump if any contamination is found. Check for source of water in fuel or debris in fuel to prevent future complaints. If no contamination is found continue to step 4. 4. Disconnect the Fuel Control Actuator (FCA). 5. Disconnect the high pressure fuel line from the fuel rail and route the high pressure fuel line to a graduated cylinder. 6. Crank the engine until fuel exits this line. This will not be high pressure fuel. 7. Crank the engine for three (3) 10 seconds intervals. NOTE: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter. Fuel flow specification's based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 4915 Fuel Pressure: Testing and Inspection In-Tank Fuel Lift Pump Flow/Diagnostic Test Procedure *IN-TANK FUEL LIFT PUMP FLOW/DIAGNOSTIC TEST PROCEDURE 1. Using the Scan tool, check for DTCs. Troubleshoot any active DTCs before performing this test. 2. Disconnect the wiring harness from the lift pump at the fuel tank module connector and inspect the pins for damage. Fix or replace any damaged component. 3. Connect a voltmeter between the fuel lift pump supply and return pins at the fuel tank module connector. 4. Turn the ignition to the on position. Use the Scan tool to actuate the fuel lift pump, record the voltage on the voltmeter. 5. If the voltage is greater than 11.5 volts, go to step 14. If the voltage is less than 11.5 volts, go to step 6 6. Using a voltmeter, measure the battery voltage to determine that the voltage is greater than 11.5 volts. If the voltage is greater than 11.5 volts, go to step 7. If the voltage is not greater than 11.5 volts, troubleshoot for low battery voltage. 7. Remove the fuel lift pump relay from the PDC. Use a voltmeter to measure the voltage at the fuel lift pump relay voltage supply pin in the PDC. If the voltage is greater than 11.5 volts, go to step 8. If the voltage is not greater than 11.5 volts, fix or replace the harness. 8. Remove the fuel lift pump relay from the PDC. Install a spare relay in place of the fuel lift pump relay. Using the Scan tool, actuate the fuel lift pump. Use a voltmeter to measure the voltage between the fuel lift pump supply and return pins at the fuel tank module connector while the fuel lift pump is actuated. If the voltage is greater than 11.5 volts, replace the fuel lift pump relay. If the voltage is not greater than 11.5 volts, go to step 9. 9. Disconnect the wiring harness from the fuel tank module. Remove the lift pump relay from the PDC. Using an Ohmmeter, measure the resistance of the fuel lift pump power supply wire between the PDC relay output pin and the fuel tank module connector. If the resistance is less than 10 ohms, go to step 10. If it is greater than 10 ohms, fix or replace the harness. 10. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using a voltmeter, measure the voltage between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the voltage is less than 1 volt, go to step 11. If the voltage is greater than 1 volt, fix or replace the harness. 11. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using an ohmmeter, measure the resistance between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the resistance is less than 10 ohms, fix or replace the harness. If the resistance is greater than 10 ohms, go to step 12. 12. Disconnect the wiring harness from the fuel tank module. Using an Ohmmeter, measure the resistance of the fuel lift pump ground wire between the fuel tank module connector and battery negative. If the resistance is less than 10 ohms, go to step 13. If the resistance is greater than 10 ohms, fix or replace the harness. 13. Disconnect the wiring harness from the fuel tank module. Using a voltmeter, measure the voltage between the fuel lift pump ground wire and battery negative. If the voltage is less than 1 volt, go to step 14. If the voltage is greater than 1 volt, fix or replace the harness. 14. Reconnect the lift pump connector. FLOW TEST. 1. Remove the fuel pump supply banjo fitting from the fuel injection pump. 2. Install fuel system test fitting 9863 onto the end of the quick connect line going to the fuel injection pump. 3. Connect one end of a section of fuel hose to the test fitting. 4. Put the other end of the fuel hose into an empty fuel container. 5. Use the scan tool to actuate the fuel lift pump. 6. While the lift pump is running, move the fuel hose from the fuel canister into a 1000ml graduated cylinder for 10 seconds. 7. Read and record the amount of fuel in the graduated cylinder after 10 seconds. 8. If you have more than 570ml in the graduated cylinder after 10 seconds, the test has successfully passed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 4916 9. If you have less than 570ml of fuel in the graduated cylinder, inspect the fuel supply line from the fuel tank to the fuel filter housing and the fuel supply line between the fuel filter housing and the high pressure fuel pump for signs of damage, replace as necessary. If no damage is found, replace the fuel filter and retest. 10.Verify the Screened Banjo Bolt at the outlet of the fuel filter is free of debris. If debris is found, rinse screen with water, blow dry and reinstall. Retest vehicle. If flow meets specification then trace back the source of debris, if flow is still below spec repair damaged component. 11. If reading is still less than 570ml in 10 seconds, remove the fuel tank and fuel tank module. Inspect for damage and/or debris in and around the fuel tank module. If module is damaged, replace and retest. 12. If the module is not damaged, replace the fuel lift pump and retest to confirm fix. Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal Air Filter Element: Service and Repair Removal REMOVAL Testing Air Cleaner Element using Filter Minder(TM) Do not attempt to unnecessarily remove top of air cleaner housing for air cleaner element inspection on diesel engines. The air cleaner (filter) housing (5) is equipped with an air Filter Minder(TM) gauge (3). This air flow restriction gauge will determine when air cleaner element is restricted and should be replaced. The Filter Minder(TM) (5) consists of a diaphragm and calibrated spring sealed inside of a plastic housing. A yellow colored disc (2) attached to diaphragm moves along a graduated scale on side of Filter Minder. After the engine has been shut off, a ratcheting device located within Filter Minder will hold yellow disc at highest restriction that air cleaner element has experienced. A drop in air pressure due to an air cleaner element restriction moves diaphragm and yellow disc will indicate size of air drop. CAUTION: Certain engine degreasers or cleaners may discolor or damage plastic housing of Filter Minder. Cover and tape Filter Minder if any engine degreasers or cleaners are to be used. To test, turn engine off. If yellow disc (2) has reached red colored zone (3) on graduated scale, air cleaner element should be replaced. Refer to Removal / Installation. Resetting Filter Minder: After air cleaner (filter) element has been replaced, press rubber button on top of Filter Minder. This will allow yellow Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 4925 colored disc to reset. After button has been pressed, yellow disc should spring back to UP position. If Filter Minder gauge has reached red colored zone, and after an examination of air cleaner (filter) element, element appears to be clean, high reading may be due to a temporary condition such as snow build-up at air intake. Temporary high restrictions may also occur if air cleaner (filter) element has gotten wet such as during a heavy rain or snow. If this occurs, allow element to dry out during normal engine operation. Reset rubber button on top of Filter Minder and retest after element has dried. Filter Removal 1. The housing cover is equipped with spring clips and is hinged with plastic tabs. Unlatch clips from top of air cleaner housing and tilt housing cover up for cover removal. 2. Remove air cleaner element from air cleaner housing (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 4926 Air Filter Element: Service and Repair Installation INSTALLATION 1. Before installing new air cleaner element (filter), clean inside of air cleaner housing. 2. Position air cleaner cover to tabs on front of air cleaner housing. Latch spring clips to seal cover to housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit Fuel Filter: Technical Service Bulletins Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit NUMBER: 14-004-11 GROUP: Fuel System DATE: April 01, 2011 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-002-10, DATED FEBRUARY 11, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE NEW PARTS. SUBJECT: Heavy Duty Filtration MOPAR Retrofit or Add On Parts Available MODELS: 2003 - 2009 (D1/DH/DR) Ram Truck (2500/3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH/DR vehicles equipped with a 5.9L Cummins engine built from 2003 model year (sales codes ETH, ETC) and DC/DH/D1/vehicles equipped with a 6.7L Cummins engine built from 2007 model year (sales code ETJ). DISCUSSION: Several fuel system add-on or retrofit parts are available to enhance the filtering capability for customers exposing their vehicles to extremely dirty conditions. Description of parts available for Cummins diesel equipped vehicles are listed below: ^ **Severe duty, frame mounted fuel filter** (application for 2004.5 - 2009 Pickup & 2007 - 2010 Cab Chassis DC). ^ 6.7L up-graded (5 & 10 micron filter-in-filter) fuel filter to retrofit earlier models (shell and element). ^ 6.7L Element only, fuel filter. ^ 5.9L & 6.7L Add-on or up-graded fuel tank vent hose kit with vent cap. ^ Filter for fuel tank vent hose, (replaces vent cap). ^ 5.9L up-graded air filter. This filter is similar in design to the current 6.7L air filter. NOTE: Do not sell p/n 05183410AA fuel filter for (bottom load style) 6.7L engines. Use 68061633AA shell and filter. NOTE: The maintenance intervals for the fuel filter(s) is 15,000 miles, 400 engine hours or 12 Months, (whichever occurs first) or more often as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 4931 PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 4932 Fuel Filter: Technical Service Bulletins Fuel System - Severe Duty Filtration Kit Availability NUMBER: 14-001-09 GROUP: Fuel DATE: January 24, 2009 SUBJECT: Severe Duty Fuel Filtration Mopar Add On Kit Available MODELS: 2005 - 2009 (D1/DH) Ram Truck (2500/3500 Pick Up) 2007 - 2009 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH vehicles equipped with a 5.9L Cummins engine built from 2005 model year and D1/DH/DC vehicles equipped with a 6.7L Cummins engine built from 2007 model year. DISCUSSION: A frame mounted supplemental filter kit is now available for the vehicles listed above. This kit includes complete instructions (K6855569AC) with all necessary components and wiring to upgrade fuel filtering to a severe duty rating. NOTE: The maintenance intervals for the fuel filters (on engine filter and added chassis mounted severe duty fuel filtration kit filter) are 15,000 miles. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 4933 Fuel Filter: Technical Service Bulletins Diesel Fuel System - Fuel/Filtering Requirements NUMBER: 14-007-06 REV. A GROUP: Fuel DATE: September 02, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-007-06, DATED AUGUST 25, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL INFORMATION REGARDING FUELING OF EARLY BUILT 2007 RAM TRUCK CAB AND CHASSIS (DC) VEHICLES. SUBJECT: Fuel And Fuel Filtering Requirements For Cummins 5.9L And 6.7L Engines OVERVIEW: This bulletin involves a discussion regarding fuel system requirements. MODELS: 2006 - 2007 (DH/D1/DC) Ram Truck (Heavy Duty) NOTE: This bulletin applies to vehicles equipped with a 5.9L High Output or a 6.7L Cummins Turbo-Diesel Engine (sales codes ETH or ETJ respectively) that were built on or after March 07, 2006 (MDH 0307XX). DISCUSSION: Current Fuel Systems: - For the diesel engine system to operate at its peak performance a high level of fuel quality must be maintained. Emission control and fuel delivery systems have advanced significantly. Care must be taken to insure that the fuel that is delivered to the engine fuel injection system is of the highest quality possible and free of contaminants. - Significant components to fuel quality are: the initial quality of the fuel (as dispensed from the service station fuel pump or bulk storage), on-vehicle fuel storage, and the on-vehicle fuel filtering of the diesel fuel prior to the fuel injection process. - Refer to the Owners Manual for fuel and fuel system information. Proper Fuel And Fuel Quality: - Use good quality diesel fuel from a reputable supplier. It is recommended that purchase of diesel fuel should be made from a service station that is known to dispense a high volume of highway diesel fuel. - ** Ultra Low Sulfur Highway Diesel Fuel (15 ppm of sulfur or less and meeting ASTM D975 grade 5-15) is required for use in Dodge Ram Trucks equipped with a 6.7L diesel engine. ** - ** The 2007 Ram Truck Cab and Chassis (DC) vehicle is equipped with a 6.7L diesel engine. This vehicle is to use Ultra Low Sulfur Highway Diesel Fuel. Due to limited availability of Ultra Low Sulfur Highway Diesel Fuel, during the initial production of this vehicle, Low Sulfur Highway Diesel Fuel (500 ppm of sulfur or less) may be used ONLY until Ultra Low Sulfur Highway Diesel fuel becomes readily available and fuel pumps that dispense Ultra Low Sulfur Highway Diesel Fuel are required to be labelled as such. This is expected to occur around October 15, 2006. ** - ** Ultra Low Sulfur Highway Diesel Fuel (preferred) or Low Sulfur Highway Diesel Fuel (500 ppm of sulfur or less) are required for use in Dodge Ram Trucks equipped with a 5.9L diesel engine. ** - A maximum blend of 5% biodiesel (B5) is acceptable as long as the biodiesel mixture meets ASTM specification D-975, D-975 - grade 5-15, and ASTM D6751. A biodiesel fuel blend that is higher than 5% is not acceptable without additional fuel processing because these higher percentage biodiesel blends contain excess amounts of moisture which exceed the water stripping capability of the on-engine final fuel filter. Should a higher percentage biodiesel fuels be used an auxiliary water stripping filter will be required. - A maximum blend of 20% biodiesel (B20) can be used by government, military, and commercial fleets who equip their vehicle(s) with an optional water separator, and adhere to the guidelines in the Department of Defense specification A-A-59693 (in addition to: ASTM specification D-975, D-975 - grade 5-15 and ASTM D6751) - Off-highway diesel fuel (i.e. farm or marine use diesel fuel) that does not meet Ultra Low Sulfur Highway or Low Sulfur Highway fuel specifications (as listed above) is NOT acceptable. Unknown sulfur and water content and unknown cetane number may adversely affect the performance of the Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 4934 engine and fuel injection system. - Fuel conditioners (additives) are not recommended and should not be required if you buy good quality fuel and follow cold weather advice supplied in the Owners Manual. Proper Bulk (Off-Vehicle) Fuel Storage: - Proper maintenance of stored fuel is essential. Diesel fuel is seldom entirely free of moisture. Fuel contaminated with moisture may develop a bacteria or "slime" that may restrict or block fuel filters and lines. - As diesel fuel is lighter than water, drain condensation no less than monthly from the diesel fuel supply/storage tanks. - Change the storage tank in-line filter regularly. This filter acts as the last filter prior to the diesel fuel entering the vehicle diesel fuel tank. Good quality diesel fuel is mandatory. If the storage tank does not have an in-line filter, then a in-line filter should be added. Refer to the table on the following page for recommended in-line filter specifications. Proper On-vehicle Fuel Storage And Filtering: - Proper on-vehicle fuel storage that prevents fuel contamination is important. - The original (OEM) vehicle fuel tank module (fuel pickup) filter performs a primary filtering of the on-vehicle diesel fuel as the fuel leaves the fuel tank and enters the fuel lines. - On-vehicle auxiliary diesel fuel tanks are often added by the vehicle owner to extend vehicle driving range. Auxiliary fuel tank systems must protect the quality of the diesel fuel just as well as the originally equipped (OEM) fuel tank that came with the vehicle when it was new. - On-vehicle auxiliary diesel fuel storage tanks must have a primary fuel filter to prevent contamination and moisture accumulation. Refer to the table on the following page for recommended filter specifications. - The prevention of moisture in the fuel system, the prevention of fuel stagnation, and the use of a primary fuel filter should all be considered in the purchase, installation, and maintenance of any auxiliary on-vehicle diesel fuel tank. Proper On-vehicle Final Fuel Filtering: - The large fuel filter mounted at the engine is the final fuel filter, water separator, fuel heater, and water drain. This filter is the final 'line of defense" when maintaining a high level of fuel quality. If the diesel fuel is contaminated or contains moisture, the engine mounted fuel filter system is the last chance to affect possible correction. - The quality of the fuel, its prior storage, and fuel handling prior to the final filter all have a significant impact on the amount of contamination and moisture entering the final fuel filter. - It is important to drain accumulated moisture/water at least monthly from the final fuel filter. Do not wait until the 'Water In Fuel" indicator illuminates before performing this maintenance. - Maintenance on the final fuel filter / water separator is important. Follow the maintenance schedule per the Owners Manual. Replace the filter more frequently if highly contaminated or high moisture content fuel is encountered. - On a 5.9L engine, if the final fuel filter is replaced due to a high moisture content diesel fuel, verify that the water sensor probes in the final filter have been cleaned. Excessive moisture may contaminate the sensor sensing probes. The 6.7L engine includes a new water-in-fuel sensor with the new final fuel filter element. - The final fuel / water separator filter must meet or exceed OEM specifications. Some aftermarket filters may not meet OEM specifications. - The final fuel I water separator filter must meet or exceed the filtration specifications listed in the table shown. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 4935 - Final fuel / water separator filters that meet the above specifications are approved for use on Cummins 5.9L and 6.7L diesel engines. - The use of non-approved fuel filters will result in engine performance deterioration, and/or possible progressive damage to the engine from foreign particle ingestion, and/or fuel system component corrosion. - It is recommended that customers use the MOPAR approved or Cummins Equivalent fuel filters to protect the engine from debris and water contamination. - The following final fuel / water separator filters are known to meet or exceed the specifications listed in the table above. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Description and Operation > Description Fuel Filter: Description and Operation Description DESCRIPTION The fuel filter/water separator assembly is located on left side of engine above the starter motor. The assembly also includes the fuel heater, water drain valve, Water-In-Fuel (WIF) sensor and a quick-connect fittings attached at the side of the fuel filter canister. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Description and Operation > Description > Page 4938 Fuel Filter: Description and Operation Operation OPERATION The fuel filter/water separator protects the fuel injection pump by removing water and contaminants from the fuel. The construction of the filter/separator allows fuel to pass through it, but helps prevent moisture (water) from doing so. Moisture collects at the bottom of the filter. Refer to the maintenance schedules for the recommended fuel filter replacement intervals. For draining of water from canister, refer to Fuel/Water Separator Removal. There is a screened quick-connect fitting that is attached at the side of the fuel filter canister. It provides additional filtering for the high pressure fuel system components. A Water-In-Fuel (WIF) sensor is attached to the bottom of fuel filter element. The fuel heater is installed into the side of the filter/separator housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal Fuel Filter: Service and Repair Removal REMOVAL Refer to maintenance schedules for recommended fuel filter replacement intervals. Draining water from fuel filter canister: The housing drain valve (3) serves two purposes. One is to partially drain the filter housing of excess water. The other is to partially drain the housing for fuel filter or heater element replacement. The filter housing (1) should be partially drained whenever the water-in-fuel warning lamp remains illuminated. (Note that lamp will be illuminated for approximately two seconds when ignition key is initially placed in ON position for a bulb check). 1. A drain hose (4) is located at the bottom of drain valve. Place drain pan under drain hose. 2. With engine not running, rotate drain valve (3) approximately two revolutions to open it. Leave open until all water and contaminants have been removed and clean fuel exits. Hand tighten drain valve after tightening. 3. If fuel heater element is being replaced, drain housing completely. Dispose of mixture in drain pan according to applicable regulations. 4. After draining operation, close and tighten drain valve (3). 5. Fuel Filter Replacement: a. Remove left front tire/wheel. b. Remove left front wheel splash shield. c. Clean all debris from around filter canister (1) and canister head. d. Disconnect WIF sensor electrical connector (5). e. Open drain valve (3) two complete revolutions. Drain approximately 1 cup of fuel into a waste canister. Dispose of fuel according to environmental regulations. f. Remove drain hose (4) from drain valve (3). g. Use an oil filter type wrench to loosen filter (1). Continue removing filter by hand. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 4941 6. After fuel filter removal, also check and clean secondary filter screen. Press button (2) on quick-connect fitting. Disconnect fitting (1) from fitting (3). Unscrew fitting (3) from canister head to expose screen. 7. Clean screen (5) and check condition of O-ring (6). 8. Water-In-Fuel (WIF) Sensor Replacement: The WIF sensor (2) is located on the bottom of the fuel filter housing. The WIF sensor is not a separately serviceable item. If diagnostics have led you to replace this sensor, then the whole fuel filter assembly (1) needs to be changed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 4942 9. Fuel Heater Element Replacement: The heater element (2) is located in the fuel filter housing (4). a. Drain fuel filter. See previous steps. b. Disconnect electrical connector (1). c. Remove two mounting screws (3). d. Remove fuel heater (2). 10. Check condition of fuel heater O-ring (2). 11. Drain Valve Replacement: The Drain Valve is located on the bottom of the fuel filter. This is not a separately serviceable item. If replacement is necessary, replace the entire filter/filter canister assembly. 12. Fuel Filter Head (Housing) Replacement: a. If equipped, remove transmission dipstick tube from filter housing. b. Remove all low-pressure fuel lines at filter housing c. Remove housing from cylinder head. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 4943 Fuel Filter: Service and Repair Installation INSTALLATION Refer to maintenance schedules for recommended fuel filter replacement intervals. 1. Fuel Filter: CAUTION: Do not pre-fill the fuel filter with fuel. Severe damage to fuel system and injection system components may result. a. The engine has a self-priming low-pressure fuel system. b. Lubricate new fuel filter O-ring with clean engine oil. c. Position new fuel filter/canister assembly (1) to housing. d. Rotate fuel filter/canister assembly (1) until it comes to a hard stop. e. Tighten the filter element an additional half-inch of rotation. f. Connect WIF sensor electrical connector (5). g. Attach drain hose (4) to drain valve (3). h. Install left front tire/wheel. i. Install left front wheel splash shield. 2. Clean screen (5). 3. Check condition of new O-ring (6) and lubricate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 4944 4. Install screen assembly into housing and tighten fitting (3) to 20 ft. lbs. (27 Nm). 5. Connect quick connect fuel supply line (1) to fitting (3). 6. Fuel Heater Element: a. Check condition of O-ring (2). b. Lubricate new element O-ring before installation. 7. Install fuel heater element (3) into fuel filter housing (4). 8. Install two fuel heater mounting screws (3) and tighten to 60 in lbs. (6.8 Nm). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 4945 9. Connect electrical connector (1). 10. Fuel Filter Head (Housing): a. Install fuel filter head to cylinder head. Tighten bolts to 32 Nm (24 ft. lbs.) torque. b. Replace sealing washers on banjo bolts and install all low-pressure fuel lines to filter housing. Tighten banjo bolts to 24 Nm (18 ft. lbs.) torque. Tighten quick-connect fitting to 27 Nm (20 ft. lbs.) torque. c. If equipped, install transmission dipstick tube to filter housing. Tighten bolt to 10 Nm (8 ft. lbs.) torque. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications DESCRIPTION The cylinder block is constructed of cast iron. The casting is a skirted design which incorporates longitudal ribs for superior strength and noise reduction. The block incorporates metric straight thread o-ring fittings at lubrication oil access points. The engine is manufactured with the cylinders being a non-sleeved type cylinder. The cylinders are numbered front to rear ; 1 to 6. The firing order is 1-5-3-6-2-4. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > System Information > Specifications Ignition Timing: Specifications IGNITION TIMING Ignition timing is not adjustable on any engine. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure (Minimum) ...................................................................................................... ...................................................................... 350 psi. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 4955 Compression Check: Testing and Inspection CYLINDER COMPRESSION/LEAKAGE TESTS CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure batteries are completely charged and the engine starter motor is in good operating condition. Otherwise, the indicated compression pressures may not be valid for diagnostic purposes. 1. Disconnect the fuel inlet line to the fuel filter housing. Plug the fuel line from the fuel tank. NOTE: Failure to plug fuel line will result in fuel leak. 2. Remove fuel transfer pump relay from PDC. 3. Start the engine and idle until the engine stalls (runs out of fuel). 4. Remove the cylinder head cover. 5. Remove the cylinder head cover carrier gasket. 6. Remove the high pressure fuel line between the cylinder head and fuel rail for the cylinder to be tested. Use tool 9864 to cap this fuel rail on the cylinder being tested. 7. Remove the fuel connector tube nut and fuel connector tube. 8. Remove the exhaust rocker lever. 9. Use Tool 9010 to remove the injector and copper sealing washer. 10. Install the exhaust rocker lever and torque to 36 Nm (27 ft. lbs.). 11. Cover the remaining rocker levers with clean shop towels to prevent any oil splatter under the hood. 12. Place a rag over the compression test tool fitting. Crank the engine for 2-3 seconds to purge any fuel that may have drained into the cylinder when the injector was removed. 13. Connect the compression test gauge. 14. Crank the engine for 5 seconds and record the pressure reading. Repeat this step three times and calculate the average of the three readings. NOTE: The minimum cylinder pressure is 350 psi. Cylinder pressure should be within 20% from cylinder to cylinder. 15. Combustion pressure leakage can be checked if cylinder pressure is below the specification. Perform the leakage test procedure on each cylinder according to the tester manufacturer instructions. 16. Upon completion of the test check and erase any engine related fault codes. CYLINDER COMBUSTION PRESSURE LEAKAGE The combustion pressure leakage test provides an accurate means for determining engine condition. Combustion pressure leakage testing will detect: - Exhaust and intake valve leaks (improper seating). - Leaks between adjacent cylinders or into water jacket. - Any causes for combustion/compression pressure loss 1. Start and operate the engine until it attains normal operating temperature. 2. Disconnect injector harness connectors. 3. Disconnect CCV tube and breather drain tube from valve cover. 4. Remove the cylinder head cover. 5. Disconnect harness from injectors. 6. Remove the cylinder head cover carrier gasket. 7. Bring the cylinder to be tested to TDC. 8. Remove the high pressure fuel line between the cylinder head and the fuel rail for the cylinder to be tested. 9. Install capping Tool 9864 onto the rail. 10. Remove the high pressure connector nut and high pressure connector with Tool 9015. 11. Remove the exhaust and intake rocker lever. 12. Use Tool # 9010 to remove the injector and copper sealing washer. 13. Install compression test Tool # 9007 into the injector bore. 14. Connect the leakage tester and perform the leakage test procedure on each cylinder according to the tester manufacturer's instructions. 15. Upon completion of the test check and erase any engine related fault codes. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments VALVE LASH ADJUSTMENT AND VERIFICATION NOTE: To obtain accurate readings, valve lash measurements AND adjustments should only be performed when the engine coolant temperature is less than 60°C (140°F). The 24-valve overhead system is a "low-maintenance" design. Routine adjustments are no longer necessary, however, measurement should still take place when troubleshooting performance problems, or upon completion of a repair that includes removal and installation of the valve train components or injectors. 1. Disconnect battery negative cables. 2. Remove cylinder head cover. 3. Using the crankshaft barring tool #7471-B, rotate crankshaft to align damper TDC mark to 12:00 o'clock position. a. If both number one cylinder rocker levers are loose, continue to next step. b. If both number one cylinder rocker levers are not loose, rotate crankshaft 360 degrees. 4. With the engine in this position, valve lash can be measured at the following rocker arms: INTAKE 1-2-4 / EXHAUST 1-3-5. Measure the valve lash by inserting a feeler gauge between the rocker arm socket and crosshead. Refer to VALVE LASH LIMIT CHART for the correct specifications. If the measurement falls within the limits, adjustment/resetting is not necessary. If measurement finds the lash outside of the limits, adjustment/resetting is required. Valve Lash Limit Chart Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > Page 4959 5. If adjustment/resetting is required, loosen the lock nut on rocker arms and turn the adjusting screw until the desired lash is obtained: - INTAKE 0.254 mm (0.010 in.) - EXHAUST 0.660 mm (0.026 in.) Tighten the lock nut to 24 Nm (18 ft. lbs.) and recheck the valve lash. 6. Using the crankshaft barring tool, rotate the crankshaft one revolution (360°) to align the damper TDC mark to the 12 o'clock position. 7. With the engine in this position, valve lash can be measured at the remaining rocker arms: INTAKE 3-5-6 / EXHAUST 2-4-6. Use the same method as above for determining whether adjustment is necessary, and adjust those that are found to be outside of the limits. 8. Install the cylinder head cover. 9. Connect the battery negative cables. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4964 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4965 Accelerator Pedal Position Sensor: Diagrams Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4966 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 4969 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) provides the Engine Control Module (ECM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 4972 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4976 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4977 Air Flow Meter/Sensor: Diagrams Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4978 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4979 Air Flow Meter/Sensor: Description and Operation OPERATION The Mass Airflow (MAF) sensor is a frequency based device. A constant voltage is applied to a heated wire on the sensor. This wire is positioned in the air cleaner air stream and is heated by the electrical current that the voltage produces. As air flows across it, it cools down. The heated wire or film is a positive temperature coefficient resistor. This means that its resistance drops when its temperature drops. The drop in resistance allows more current to flow through it in order to maintain the programmed temperature. This current is changed to a frequency which is sent to the Engine Control Module (ECM) and interpreted as air flow. Adjustments for air temperature and humidity are taken into consideration because they also affect the temperature of the heated wire or film. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL The Mass Airflow Sensor (5) is located on the air cleaner cover (8). 1. Disconnect electrical connector (6) at sensor. 2. Remove two mounting screws (4). 3. Remove sensor from air cleaner cover. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 4982 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (4). 4. Install electrical connector (6). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations Intake Air Temperature Sensor: Component Locations Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4987 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4988 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4989 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4990 Component Location - 4 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4991 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4992 Cab/Chassis Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. Pick Up Models Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4993 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4994 Intake Air Temperature Sensor: Connector Locations Component ID: 406 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (6.7L DH) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4995 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4996 Component Location - 7 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4997 Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 IAT SIGNAL K21 20DB/LG 2 SENSOR GROUND K900 20DB/DG Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4998 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4999 Component Location - 7 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 5000 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor Intake Air Temperature Sensor: Diagrams Intake Air Temperature Sensor Component ID: 406 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (6.7L DH) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5003 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5004 Component Location - 7 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5005 Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 IAT SIGNAL K21 20DB/LG 2 SENSOR GROUND K900 20DB/DG Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5006 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5007 Component Location - 7 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5008 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5009 Intake Air Temperature Sensor: Diagrams Sensor-Temperature/Pressure-MAP Component ID: 427 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A SENSOR GROUND K210 18DB/TN B INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG C 5 VOLT SUPPLY F855 18PK/YL D BOOST PRESSURE SENSOR SIGNAL K37 18LB Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5010 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 BOOST PRESSURE SENSOR SIGNAL K37 18BR 2 5 VOLT SUPPLY F855 18PK/YL 3 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 3 CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR K735 18BR/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5011 4 SENSOR GROUND K916 18BR/OR Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5012 Intake Air Temperature Sensor: Diagrams Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5013 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5014 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5015 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5016 Component Location - 4 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5017 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5018 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Sensor-Temperature/Pressure-Intake Intake Air Temperature Sensor: Description and Operation Sensor-Temperature/Pressure-Intake OPERATION The Inlet Air Temperature/Pressure Sensor is a combination dual-function sensor. The sensor element extends into the intake air stream at the top of the air filter housing. Ambient air temperature as well as barometric pressure is monitored by this sensor. The Engine Control Module (ECM) monitors signals from this sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Sensor-Temperature/Pressure-Intake > Page 5021 Intake Air Temperature Sensor: Description and Operation Sensor-Temperature/Pressure-MAP OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet Intake Air Temperature Sensor: Service and Repair Sensor-Temperature/Pressure-Inlet Removal REMOVAL The Inlet Air Temperature/Pressure Sensor (3) is located on the air cleaner cover. 1. Disconnect electrical connector (7) at sensor. 2. Remove mounting screw (2). 3. Remove sensor from air cleaner cover. 4. Check condition of sensor O-ring. Installation INSTALLATION 1. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 5024 2. Position sensor (3) into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (2). 4. Install electrical connector (7). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 5025 Intake Air Temperature Sensor: Service and Repair Sensor-Temperature/Pressure-MAP Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Pick Up Models REMOVAL-PICK UP MODELS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 5026 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 5027 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Description and Operation Barometric Pressure Sensor: Description and Operation OPERATION The Inlet Air Temperature/Pressure Sensor is a combination dual-function sensor. The sensor element extends into the intake air stream at the top of the air filter housing. Ambient air temperature as well as barometric pressure is monitored by this sensor. The Engine Control Module (ECM) monitors signals from this sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Service and Repair > Removal Barometric Pressure Sensor: Service and Repair Removal REMOVAL The Inlet Air Temperature/Pressure Sensor (3) is located on the air cleaner cover. 1. Disconnect electrical connector (7) at sensor. 2. Remove mounting screw (2). 3. Remove sensor from air cleaner cover. 4. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Service and Repair > Removal > Page 5033 Barometric Pressure Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor (3) into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (2). 4. Install electrical connector (7). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Component ID: 388 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 BATT TEMP SIGNAL K25 20DB/VT 2 SENSOR GROUND K900 20DB/DG Component Location - 32 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 5037 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 5038 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 5039 Battery Temperature Sensor: Diagrams Component ID: 388 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 BATT TEMP SIGNAL K25 20DB/VT 2 SENSOR GROUND K900 20DB/DG Component Location - 32 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 5040 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 5041 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Description DESCRIPTION The Battery Temperature Sensor (BTS) is used only on the diesel engine. It is attached to the battery tray located under the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description > Page 5044 Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Operation OPERATION The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Removal REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4) . 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3) . 3. Disconnect sensor from engine wire harness electrical connector. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal > Page 5047 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Installation INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5052 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5053 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5054 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5055 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5056 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5057 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5058 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5059 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5060 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5061 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5062 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5063 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5064 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5065 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5066 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5067 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5068 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5069 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5073 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5074 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5075 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5076 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5077 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5078 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5079 Camshaft Position Sensor: Diagrams Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5080 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5081 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5082 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5083 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5084 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5085 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) is located below the fuel injection pump. It is bolted to the back of the timing gear cover. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 5088 Camshaft Position Sensor: Description and Operation Operation 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) contains a hall effect device. A rotating target wheel (tonewheel) for the CMP is located on the front timing gear. This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CMP. When the leading edge of the tonewheel notch passes the tip of the CMP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CMP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The CMP provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses the CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal Camshaft Position Sensor: Service and Repair Removal 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) on the diesel engine is located below the fuel injection pump (1). It is bolted to the back of the timing gear cover. 1. Disconnect electrical connector (5) at CMP sensor. 2. Remove sensor mounting bolt (6). 3. Carefully twist sensor from timing gear cover. 4. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 5091 Camshaft Position Sensor: Service and Repair Installation 5.9L/6.7L DIESEL The CMP (1) is located on the back of the timing gear cover. 1. Clean out machined hole in back of timing gear cover. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into timing gear cover with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to back of timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in.lbs.). 5. Connect electrical connector to sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5096 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5097 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5098 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5099 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5100 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5101 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5102 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5103 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5106 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5107 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5108 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5109 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5110 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5111 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5112 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5113 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 5116 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 5119 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations Crankcase Pressure Sensor: Locations Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 5123 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 5124 Crankcase Pressure Sensor: Diagrams Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 5125 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 5126 Crankcase Pressure Sensor: Description and Operation OPERATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). The CP sensor monitors crankcase pressure that builds up as the result of combustion gas blow-by. The Engine Control Module (ECM) uses data from the CP sensor to determine the condition of the crankcase breather (ventilation) filter. The ECM can also determine if a crankcase breather (ventilation) filter is present. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal Crankcase Pressure Sensor: Service and Repair Removal REMOVAL The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Remove mounting screw (6). 2. Disconnect electrical connector (7). 3. Remove sensor (5) from valve cover (4). 4. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal > Page 5129 Crankcase Pressure Sensor: Service and Repair Installation INSTALLATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Check condition of sensor O-ring. 2. Install sensor (5) into valve cover (4). 3. Install mounting screw (6). Tighten to 3 Nm (27 in. lbs.) torque. 4. Connect electrical connector (7). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Description Coolant Temperature Sensor/Switch (For Computer): Description and Operation Description DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Description > Page 5134 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Operation OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air-fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: - for engine coolant temperature gauge operation through CAN Bus communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid on/off times - Cooling fan control - Temperature gauge operation - A/C cutoff at high coolant temperatures - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Removal Coolant Temperature Sensor/Switch (For Computer): Service and Repair Removal 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL WARNING: Hot, pressurized coolant can cause injury by scalding. Cooling system must be partially drained before removing the coolant temperature sensor. 1. Partially drain the cooling system. ECT LOCATION - 5.9L DIESEL 2. Remove heat shield (if equipped). 3. Disconnect the electrical connector (2) from the ETC sensor (3). 4. Remove the ETC sensor from the cylinder head. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Removal > Page 5137 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Installation 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL 1. Install sensor (1 or 3) to engine. 2. Tighten sensor to 18 Nm (13 ft. lbs.) torque. ECT LOCATION - 5.9L DIESEL 3. Connect electrical connector (2) to ETC sensor (1 or 3). 4. Install heat shield (if equipped). 5. Replace any lost engine coolant. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5141 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5142 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5143 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5144 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5145 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5146 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5147 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5148 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5149 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5150 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5151 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5152 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5153 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5154 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5155 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5156 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5157 Crankshaft Position Sensor: Diagrams Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5158 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5159 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5160 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5161 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5162 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5163 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5164 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5165 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5166 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5167 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5168 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5169 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5170 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5171 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5172 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 5173 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The Crankshaft Position Sensor (CKP) on the diesel engine is attached at the front / left side of the engine next to the engine harmonic balancer (crankshaft damper). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 5176 Crankshaft Position Sensor: Description and Operation Operation OPERATION The Crankshaft Position Sensor (CKP) (5) is the primary engine speed indicator for the engine after the engine is running. The CKP contains a hall effect device. A rotating, notched target wheel (tonewheel) (3) for the CKP is attached to the engine harmonic balancer (2). This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CKP. When the leading edge of the tonewheel notch passes the tip of the CKP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CKP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The Camshaft Position Sensor (CMP) also provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses this CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal Crankshaft Position Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle 2. Disconnect electrical connector (4) at CKP sensor. 3. Remove 1 sensor mounting bolt (3). 4. Remove CKP sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 5179 Crankshaft Position Sensor: Service and Repair Installation INSTALLATION 1. Position and install CKP sensor (5) to engine. 2. Install 1 sensor mounting bolt and tighten to 9 Nm (80 in. lbs.) torque. 3. Install electrical connector (4) to CKP sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Data Link Connector Data Link Connector: Locations Data Link Connector Component ID: 79 Component : DATA LINK CONNECTOR Connector: Name : DATA LINK CONNECTOR Color : BLACK # of pins : 16 Pin Description Circuit 1-2-3-4 GROUND Z11 18BK/LG 5 GROUND Z111 18BK/WT 6 DIAGNOSTIC CAN C (+) D52 20WT/LB 7 SCI TRANSMIT (ECM) D21 18WT/BR 7 SCI TRANSMIT (PCM) D21 18WT/BR 8-9 SCI RECEIVE (TCM) D16 18WT/OR 10 - 11 - 12 SCI RECEIVE (ECM) D20 20WT/LG 12 SCI RECEIVE (PCM) D20 20WT/LG 13 - 14 DIAGNOSTIC CAN C (-) D51 20WT/BR 15 SCI TRANSMIT (TCM) D15 18WT/DG 16 FUSED B(+) A114 18GY/RD Component Location - 49 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Data Link Connector > Page 5184 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Data Link Connector > Page 5185 Data Link Connector: Locations Port-Diagnostic Component ID: 232 Component : PORT-DIAGNOSTIC Connector: Name : PORT-DIAGNOSTIC Color : # of pins : 3 Qualifier : (6.7L) A DIAGNOSTIC PORT LOW DATA LINK D132 18WT B DIAGNOSTIC PORT HIGH DATA LINK D133 18WT/OR C-Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Data Link Connector > Page 5186 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5189 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5190 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5191 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5192 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5193 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5194 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5195 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5196 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5197 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5198 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5199 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5200 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5201 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5202 Data Link Connector: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5203 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5204 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5205 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5206 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5207 Data Link Connector: Connector Views Data Link Connector Component ID: 79 Component : DATA LINK CONNECTOR Connector: Name : DATA LINK CONNECTOR Color : BLACK # of pins : 16 Pin Description Circuit 1-2-3-4 GROUND Z11 18BK/LG 5 GROUND Z111 18BK/WT 6 DIAGNOSTIC CAN C (+) D52 20WT/LB 7 SCI TRANSMIT (ECM) D21 18WT/BR 7 SCI TRANSMIT (PCM) D21 18WT/BR 8-9 SCI RECEIVE (TCM) D16 18WT/OR 10 - 11 - 12 SCI RECEIVE (ECM) D20 20WT/LG 12 SCI RECEIVE (PCM) D20 20WT/LG 13 - 14 DIAGNOSTIC CAN C (-) D51 20WT/BR 15 SCI TRANSMIT (TCM) D15 18WT/DG 16 FUSED B(+) A114 18GY/RD Component Location - 49 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5208 Port-Diagnostic Component ID: 232 Component : PORT-DIAGNOSTIC Connector: Name : PORT-DIAGNOSTIC Color : # of pins : 3 Qualifier : (6.7L) A DIAGNOSTIC PORT LOW DATA LINK D132 18WT B DIAGNOSTIC PORT HIGH DATA LINK D133 18WT/OR C-Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5209 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Description and Operation > Description Data Link Connector: Description and Operation Description DESCRIPTION The Data Link Connector (DLC) (3) is a 16-way molded plastic connector insulator on a dedicated take out of the instrument panel wire harness. This connector is located at the lower edge of the instrument panel, outboard of the steering column. The connector insulator is retained by integral snap features within a rectangular cutout in the lower instrument panel reinforcement (2), just below the lower edge of the instrument panel steering column opening cover (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Description and Operation > Description > Page 5212 Data Link Connector: Description and Operation Operation OPERATION The Data Link Connector (DLC) is an industry-standard 16-way connector that permits the connection of a diagnostic scan tool to the Controller Area Network (CAN) data bus for interfacing with, configuring, and retrieving Diagnostic Trouble Code (DTC) data from the electronic modules that reside on the data bus network of the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Indicator > Component Information > Description and Operation > Description Electronic Throttle Control Indicator: Description and Operation Description DESCRIPTION An Electronic Throttle Control (ETC) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional 5.7 liter gasoline engine, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The ETC indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Electronic Throttle Control in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ETC indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Indicator > Component Information > Description and Operation > Description > Page 5217 Electronic Throttle Control Indicator: Description and Operation Operation OPERATION The Electronic Throttle Control (ETC) indicator gives an indication to the vehicle operator when the ETC system, or a circuit or component of the system is ineffective. The ETC indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The ETC indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the ETC indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the ETC indicator is illuminated for about six seconds. The entire bulb test is a function of the PCM. - ETC Indicator Lamp-On Message - Each time the cluster receives an electronic ETC indicator lamp-ON message from the PCM, the ETC indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the PCM message. The indicator remains illuminated solid or continues to flash for about 12 seconds or until the cluster receives a lamp-OFF message from the PCM, whichever is longer. If the indicator is illuminated solid with the engine running the vehicle will usually remain drivable. If the indicator is flashing with the engine running the vehicle may require towing. A flashing indicator means the ETC system requires immediate service. The indicator will be extinguished when the ignition switch is turned to the OFF position. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the PCM for three consecutive seconds, the ETC indicator is illuminated. The indicator remains illuminated until the cluster receives a single lamp-OFF message from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the ETC indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The actuator test illumination of the ETC indicator is a function of the PCM. The PCM continually monitors the ETC system circuits and sensors to decide whether the system is in good operating condition. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the PCM sends a lamp-ON message after the bulb test, it indicates that the PCM has detected an ETC system malfunction or that the ETC system is ineffective. The PCM will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the ETC indicator fails to illuminate due to an open or short in the cluster ETC indicator circuit, the cluster sends a message notifying the PCM of the condition, then the EMIC and the PCM will each store a DTC. For proper diagnosis of the ETC system, the PCM, the EMIC, the CAN data bus or the electronic communication related to ETC indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness Technical Service Bulletin # K01 Date: 100510 Recall - ECM Update For OBD Readiness May 2010 Dealer Service Instructions for: California Emissions Recall K01 Reprogram ECM OBD Readiness Effective immediately all repairs on involved vehicles are to be performed according to this notification. Service Bulletin 18-038-09 is no longer applicable for the involved vehicles only. Models 2003 (DR) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETC) and a California emission control system (sales code NAE). 2006-2007 (DH/D1) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETH) and a California emission control system (sales code NAE). 2007 (DC) Dodge Ram Truck (3500 series cab chassis) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ) and a California emission control system (sales code NAE) built through January 5, 2007 (MDH010508). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process or GRS DealerCONNECT functions. Subject The Engine Control Module (ECM) on about 25,208 of the above vehicles may fail to accurately report diagnostic system information with some generic scan tools. This may cause the vehicle to be rejected or fail an Inspection/Maintenance Test (also known as a Smog Check). Repair The Engine Control Module (ECM) must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Part Number Description 04275086AB Authorized Modifications Label Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5226 The special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the label plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5227 To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: The DRBIII(R) must be used to perform this recall on 2003 Model Year (MY) vehicles. The 2003 MY procedure is found in Section D of the Service Procedure. Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall on 2006-2007 MY vehicles. This procedure must be performed with software release level 10.03 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5228 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's" button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section E. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5229 h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section E. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5230 e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 10. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 9. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 10. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 11. Continue with Section E. Install Authorized Modification Label. D. Reprogram the ECM Using DRBIII(R): The DealerCONNECT System, DRBIII(R) (Diagnostic Readout Box scan tool), CH7000A flash cable and CH7035B data cable are required to perform this repair. Do not attempt to perform the flash procedure using an outdated CH7000/CH7001 flash cable. NOTE: Whenever a controller is reprogrammed, the software in the DRBIII scan tool must be programmed with the latest revision level available. NOTE: If the flash process is interrupted or aborted, the flash should be restarted and then follow the directions on the DRBIII scan tool. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5231 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the DRBIII CH7000A flash cable from the DRBIII scan tool to the data link connector located inside the vehicle under the steering column. 3. Connect the CH7035B data cable from the DealerCONNECT machine to the MDS port on the DRBIII scan tool. 4. Place the vehicle's ignition key in the "RUN" position. 5. From the DealerCONNECT "WELCOME" screen, enter your "User I.D.," "Password" and "Dealer Code". 6. From the DealerCONNECT "HOME PAGE" select the "SERVICE" tab. 7. From the "SERVICE" tab screen select "TechTOOLS". 8. If the DRBIII scan tool does not "Auto Connect" select # 2 on the DRBIII key pad "Connect to TechCONNECT". 9. After the "Auto Connect" process is complete, select "READ PART NUMBER(S) FROM VEHICLE" on the TechCONNECT screen. 10. Continue following the TechCONNECT on-screen instructions. 11. Select the applicable update calibration. 12. Select the "DRBIII" button located at the bottom of the TechCONNECT monitor screen. 13. Select the "DOWNLOAD / UPDATE" button located next to the "DRBIII" button. NOTE: The system software will automatically download to the DRBIII scan tool. 14. After the software download to the DRBIII scan tool is complete, close the "DOWNLOAD / UPDATE PROGRESS" window. 15. Disconnect the DRBIII scan tool from the TechCONNECT CH7035B data cable. 16. Select # 1 "RETURN TO NORMAL MODE" on the DRBIII scan tool. 17. Use the following procedure to download the flash from the DRBIII scan tool to the vehicle. a. Select # 7 "VEHICLE FLASH" on the DRBIII scan tool. b. Follow the directions displayed on the DRBIII scan tool screen. c. After the reprogramming is complete, record the new module part number displayed on the DRBIII scan tool screen. d. Press the "PAGE BACK" button on the DRBIII scan tool. 18. Due to the ECM flash procedure, Diagnostic Trouble Codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS, ORC) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules, record the trouble codes, and erase the trouble codes using the following procedure: a. Turn the vehicle's ignition key to the "RUN" position. b. From the DRBIII scan tool Main Menu select # 1 "DRBIII Stand-Alone". c. From the DRBIII scan tool Stand-Alone menu select # 3 "Vehicle Module Scan". d. From the DRBIII scan tool Vehicle Module Scan menu select # 1 "1998 - 2005 Module Scan". e. Select "YES" on the DRBIII scan tool key pad to scan for DTC's. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5232 f. Follow the instructions on the DRBIII scan tool screen. g. Once the scanning process is complete, the DRBIII scan tool will display a list of all the modules. Modules on the list that have an asterisk next to them have DTC's that need to be cleared. h. Select the module that needs to have the DTC's cleared and follow the instructions on the DRBIII scan tool screen to clear the DTC's. i. Turn the vehicle's ignition key to the "OFF" position. NOTE: Erase any DTC's in the ECM only after all other modules have had their DTC's erased. 19. Disconnect the DRBIII scan tool from the vehicle. 20. Turn off the battery charger and disconnect it from the vehicle. 21. Continue with Section E. Install Authorized Modification Label. E. Install the Authorized Modifications Label: 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5233 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5238 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5239 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5240 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5241 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5242 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5243 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5244 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-003-10 > Sep > 10 > Engine Controls ECM Update for Fan Clutch Operation Engine Control Module: Customer Interest Engine Controls - ECM Update for Fan Clutch Operation NUMBER: 07-003-10 GROUP: Cooling DATE: September 09, 2010 SUBJECT: High Coolant Temperatures On Vehicles Equipped With Snow Plows OVERVIEW: This bulletin provides information on how to program the Engine Control Module (ECM) to force the fan clutch to fully engage at all operating conditions MODELS: 2007 - 2010 DC/DM Ram 3500/4500/5500 Cab Chassis Trucks 2011 DD/DP Ram 3500/4500/5500 Cab Chassis Trucks NOTE: This bulletin applies to vehicles equipped with the 6.7L Cummins Diesel engine (Sales Code ETJ) DISCUSSION: Customers that operate their vehicle with a snowplow attached to the vehicle may cause the airflow passing through the radiator to be disrupted resulting in higher than normal engine temperatures The 6~7L Cummins ECM is equipped with software that can fully engage the fan clutch to allow an increase of airflow through the radiator Customers can initiate the fan clutch operation by performing the following button sequence NOTE: 2007 early 2009 models were not originally equipped with the fan clutch software however, recently released software does include this enhancement Ensure that the ECM software is at the latest level and if not, flash the ECM Refer to Service Bulletin 18-020-10 for additional information 1. Turn the ignition key to the run position or start the truck 2. Simultaneously press and release the Cruise Control "Cancel" button/lever and the "Exhaust Brake" button. Repeat this sequence four times within five seconds. The chime will sound twice as an audible indicator that the function is engaged 3. To disable the function, repeat the same procedure The chime will sound four times as an audible indicator that the function is disengaged NOTE: Customer's should be made aware that an increase in fan noise and a decrease in fuel economy may result when using this feature. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls Engine Systems/Exhaust Enhancements Engine Control Module: Customer Interest Engine Controls - Engine Systems/Exhaust Enhancements NUMBER: 18-020-10 GROUP: Vehicle Performance DATE: June 10, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-06, DATED DECEMBER 05, 2006 AND 18-001-09, DATED JANUARY 21, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. Either wiTECH OR StarMOBILE DESKTOP CLIENT can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. StarMOBILE® SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. SUBJECT: FLASH: Engine Systems And Exhaust Aftertreatment Systems Enhancements OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement based on customer use and mileage accumulation. This bulletin involves: ^ Selectively erasing and reprogramming the Engine Control Module (PCM), 2007 - 2010 MY. ^ Selectively erasing and reprogramming the Cab Compartment Node (CCN), 2007 & 2008 MY. ^ If CCN is updated; provide a Customer Information Sheet explaining the overhead display messages. ^ One of several software changes allows for "Net Zero" and "Net Reduction" which will cause noticeable changes in idle speeds. Customers should be informed of these changes. They are explained in DISCUSSION, Improvements that address erroneous MIL illumination for DTC P0106, P0191, P2262 and P2299 DTC's, (spelled out in DISCUSSION below). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. MODELS: 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) 2008 - 2010 (DM) Ram Truck (4500/5500 Cab Chassis) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). NOTE: For some 2007 MY vehicles, the ECM flash is addressed in Recall K01, Dated May, 2010. Where applicable. please use the Recall to update the ECM and this bulletin to update the CCN software. DISCUSSION: Cab chassis trucks equipped with a 6.7L Cummins diesel have a number of software improvements available. This latest Service Bulletin (SB) will include improvements to prevent erroneous Malfunction Indicator Lamp (MIL) illumination: ^ P000F - Fuel System Over Pressure Relief Valve Activated Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls Engine Systems/Exhaust Enhancements > Page 5254 ^ P0087 - Fuel Rail Pressure Too Low ^ P0106 - Manifold Absolute Pressure Sensor Performance ^ P0191 - Fuel Rail Pressure Sensor Circuit Performance ^ P1011 - Fuel Pump Delivery Pressure Too Low ^ P2299 - Brake Pedal Position / Accelerator Pedal Position Incompatible ^ P2262 - Turbocharger Boost Pressure Not Detected - Mechanical Other updates will include the following operational and diagnostic improvements: 1. Stationary DeSoot is now available with this software. This feature works similar to pick up truck (DH/D1) models. 2. New DTC added for P2563 - Turbocharger Boost Control Position Sensor Performance. This DTC indicates diminished variable geometry turbocharger travel, which is resolved by replacing the turbocharger. Diagnosis and repair procedures for the DTC have been published in DTC-Based Diagnostics in TechConnect. 3. The latest PCM software includes a new extended idle feature to accommodate the extended idle times present in some duty cycles. This feature may help to reduce the accumulation of soot in the exhaust aftertreatment system when the engine is idling for an extended period of time. Briefly how this feature works: a. As needed, the engine enters an idling mode which dramatically reduces the rate of soot accumulation in the diesel particulate filter (called "Net Zero"). Further, under extended idle periods of 5 minutes or longer, the engine enters a mode which reduces the amount of soot accumulated in the diesel particulate filter (called "Net Reduction"). While in these modes, the idle speed increases to 900 RPM for a period of time. The idle speed may return to normal idle speed and then return to 900 RPM to repeat this cycle during very long idle periods. b. These modes occur automatically depending on the need to regenerate the DPF as long as the vehicle is not driven over 20 MPH or operated at high load. If the vehicle is driven over 20 MPH normal mobile desoot will occur automatically. 4. New scan tool driven fuel system diagnostic tests (same as previously released in the pick up) now available for cab chassis. DIAGNOSIS: 1. Using the scan tool, determine current software level of the PCM and CCN. Record on the repair order, for later use, the current PCM and CCN software level part numbers. Proceed to the next step. 2. Compare the current PCM software level part number with software available in the scantool. Determine if the current PCM software level part number, recorded in Step # 1, is programmable to a higher level. 3. Is the part number of the current PCM level software (recorded in Step # 1) at the latest level listed in the scan tool? a. If YES >> then the PCM DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. b. If NO >> then the PCM DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. 4. Is the vehicle a 2007 OR 2008 MY? a. Yes >>> Proceed to Step # 5. b. No >>> 2009 MY proceed to the REPAIR PROCEDURE as required. 5. Determine if the current CCN module level software part number, that was recorded earlier in Step # 1, is one of the following (or with a higher suffix): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls Engine Systems/Exhaust Enhancements > Page 5255 a. 05172187AH (or higher) = 2007 DC (3500). b. 05172334AG (or higher) = 2008 DC (3500) / DM (3500/4500). c. 2009 & 2010 MY vehicles came equipped with proper CCN software. 6. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 5? a. If YES >>> then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. b. If NO >>> then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. PARTS REQUIRED: REPAIR PROCEDURE; ECM MODULE REPROGRAM: NOTE: The wiTECH diagnostic application is the preferred method for flashing ECU's. Help using the wiTECH diagnostic application for flashing an ECU is available by selecting "Help" then "Help Contents" at the top of the wiTECH diagnostic application window. NOTE: The wiTECH software level must be at release 10.04 or higher to perform this procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. If required, as determined in DIAGNOSIS, above: reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > 8E - Electronic Control Modules >MODULE, Engine Control, Diesel > Service Information > Standard Procedure > PCM/ECM Programming - DIESEL. After PCM reprogramming, the following must be performed: a. Clear any DIG's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 3. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. 4. If required, as determined in DIAGNOSIS, above: reprogram the CCN using one of the following procedures, (based on scan tool use). 5. Was it determined in DIAGNOSIS, Step # 6 above, the CCN required updating? a. Yes >>> Proceed to appropriate CCN Module Reprogram Procedure Below, based on the scantool used. b. No >>> Repair is complete. NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls Engine Systems/Exhaust Enhancements > Page 5256 NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. CCN MODULE REPROGRAM - USING wiTECH(R): 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id and "Password", then select "OK". 6. Select the "Next tab at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash" screen follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF position", remove the wiPOD(R) and battery charger from the vehicle. StarMOBILE(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident" flash file for statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls Engine Systems/Exhaust Enhancements > Page 5257 b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step Se, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number (displayed at the end of the "Resident flash file for statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls Engine Systems/Exhaust Enhancements > Page 5258 Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "Exhaust Filter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required - See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test Engine Control Module: Customer Interest Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 5263 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-003-10 > May > 10 > Engine, A/T Controls MIL ON/DTCs P0711/P0776 Set Engine Control Module: Customer Interest Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-003-10 > May > 10 > Engine, A/T Controls MIL ON/DTCs P0711/P0776 Set > Page 5268 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-003-10 > May > 10 > Engine, A/T Controls MIL ON/DTCs P0711/P0776 Set > Page 5269 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls CCN Update For Recall J35 Engine Control Module: Customer Interest Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls CCN Update For Recall J35 > Page 5274 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls CCN Update For Recall J35 > Page 5275 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls CCN Update For Recall J35 > Page 5276 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls CCN Update For Recall J35 > Page 5277 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 07-003-10 > Sep > 10 > Engine Controls - ECM Update for Fan Clutch Operation Engine Control Module: All Technical Service Bulletins Engine Controls - ECM Update for Fan Clutch Operation NUMBER: 07-003-10 GROUP: Cooling DATE: September 09, 2010 SUBJECT: High Coolant Temperatures On Vehicles Equipped With Snow Plows OVERVIEW: This bulletin provides information on how to program the Engine Control Module (ECM) to force the fan clutch to fully engage at all operating conditions MODELS: 2007 - 2010 DC/DM Ram 3500/4500/5500 Cab Chassis Trucks 2011 DD/DP Ram 3500/4500/5500 Cab Chassis Trucks NOTE: This bulletin applies to vehicles equipped with the 6.7L Cummins Diesel engine (Sales Code ETJ) DISCUSSION: Customers that operate their vehicle with a snowplow attached to the vehicle may cause the airflow passing through the radiator to be disrupted resulting in higher than normal engine temperatures The 6~7L Cummins ECM is equipped with software that can fully engage the fan clutch to allow an increase of airflow through the radiator Customers can initiate the fan clutch operation by performing the following button sequence NOTE: 2007 early 2009 models were not originally equipped with the fan clutch software however, recently released software does include this enhancement Ensure that the ECM software is at the latest level and if not, flash the ECM Refer to Service Bulletin 18-020-10 for additional information 1. Turn the ignition key to the run position or start the truck 2. Simultaneously press and release the Cruise Control "Cancel" button/lever and the "Exhaust Brake" button. Repeat this sequence four times within five seconds. The chime will sound twice as an audible indicator that the function is engaged 3. To disable the function, repeat the same procedure The chime will sound four times as an audible indicator that the function is disengaged NOTE: Customer's should be made aware that an increase in fan noise and a decrease in fuel economy may result when using this feature. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Systems/Exhaust Enhancements NUMBER: 18-020-10 GROUP: Vehicle Performance DATE: June 10, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-06, DATED DECEMBER 05, 2006 AND 18-001-09, DATED JANUARY 21, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. Either wiTECH OR StarMOBILE DESKTOP CLIENT can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. StarMOBILE® SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. SUBJECT: FLASH: Engine Systems And Exhaust Aftertreatment Systems Enhancements OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement based on customer use and mileage accumulation. This bulletin involves: ^ Selectively erasing and reprogramming the Engine Control Module (PCM), 2007 - 2010 MY. ^ Selectively erasing and reprogramming the Cab Compartment Node (CCN), 2007 & 2008 MY. ^ If CCN is updated; provide a Customer Information Sheet explaining the overhead display messages. ^ One of several software changes allows for "Net Zero" and "Net Reduction" which will cause noticeable changes in idle speeds. Customers should be informed of these changes. They are explained in DISCUSSION, Improvements that address erroneous MIL illumination for DTC P0106, P0191, P2262 and P2299 DTC's, (spelled out in DISCUSSION below). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. MODELS: 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) 2008 - 2010 (DM) Ram Truck (4500/5500 Cab Chassis) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). NOTE: For some 2007 MY vehicles, the ECM flash is addressed in Recall K01, Dated May, 2010. Where applicable. please use the Recall to update the ECM and this bulletin to update the CCN software. DISCUSSION: Cab chassis trucks equipped with a 6.7L Cummins diesel have a number of software improvements available. This latest Service Bulletin (SB) will include improvements to prevent erroneous Malfunction Indicator Lamp (MIL) illumination: ^ P000F - Fuel System Over Pressure Relief Valve Activated Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 5287 ^ P0087 - Fuel Rail Pressure Too Low ^ P0106 - Manifold Absolute Pressure Sensor Performance ^ P0191 - Fuel Rail Pressure Sensor Circuit Performance ^ P1011 - Fuel Pump Delivery Pressure Too Low ^ P2299 - Brake Pedal Position / Accelerator Pedal Position Incompatible ^ P2262 - Turbocharger Boost Pressure Not Detected - Mechanical Other updates will include the following operational and diagnostic improvements: 1. Stationary DeSoot is now available with this software. This feature works similar to pick up truck (DH/D1) models. 2. New DTC added for P2563 - Turbocharger Boost Control Position Sensor Performance. This DTC indicates diminished variable geometry turbocharger travel, which is resolved by replacing the turbocharger. Diagnosis and repair procedures for the DTC have been published in DTC-Based Diagnostics in TechConnect. 3. The latest PCM software includes a new extended idle feature to accommodate the extended idle times present in some duty cycles. This feature may help to reduce the accumulation of soot in the exhaust aftertreatment system when the engine is idling for an extended period of time. Briefly how this feature works: a. As needed, the engine enters an idling mode which dramatically reduces the rate of soot accumulation in the diesel particulate filter (called "Net Zero"). Further, under extended idle periods of 5 minutes or longer, the engine enters a mode which reduces the amount of soot accumulated in the diesel particulate filter (called "Net Reduction"). While in these modes, the idle speed increases to 900 RPM for a period of time. The idle speed may return to normal idle speed and then return to 900 RPM to repeat this cycle during very long idle periods. b. These modes occur automatically depending on the need to regenerate the DPF as long as the vehicle is not driven over 20 MPH or operated at high load. If the vehicle is driven over 20 MPH normal mobile desoot will occur automatically. 4. New scan tool driven fuel system diagnostic tests (same as previously released in the pick up) now available for cab chassis. DIAGNOSIS: 1. Using the scan tool, determine current software level of the PCM and CCN. Record on the repair order, for later use, the current PCM and CCN software level part numbers. Proceed to the next step. 2. Compare the current PCM software level part number with software available in the scantool. Determine if the current PCM software level part number, recorded in Step # 1, is programmable to a higher level. 3. Is the part number of the current PCM level software (recorded in Step # 1) at the latest level listed in the scan tool? a. If YES >> then the PCM DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. b. If NO >> then the PCM DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. 4. Is the vehicle a 2007 OR 2008 MY? a. Yes >>> Proceed to Step # 5. b. No >>> 2009 MY proceed to the REPAIR PROCEDURE as required. 5. Determine if the current CCN module level software part number, that was recorded earlier in Step # 1, is one of the following (or with a higher suffix): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 5288 a. 05172187AH (or higher) = 2007 DC (3500). b. 05172334AG (or higher) = 2008 DC (3500) / DM (3500/4500). c. 2009 & 2010 MY vehicles came equipped with proper CCN software. 6. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 5? a. If YES >>> then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. b. If NO >>> then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. PARTS REQUIRED: REPAIR PROCEDURE; ECM MODULE REPROGRAM: NOTE: The wiTECH diagnostic application is the preferred method for flashing ECU's. Help using the wiTECH diagnostic application for flashing an ECU is available by selecting "Help" then "Help Contents" at the top of the wiTECH diagnostic application window. NOTE: The wiTECH software level must be at release 10.04 or higher to perform this procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. If required, as determined in DIAGNOSIS, above: reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > 8E - Electronic Control Modules >MODULE, Engine Control, Diesel > Service Information > Standard Procedure > PCM/ECM Programming - DIESEL. After PCM reprogramming, the following must be performed: a. Clear any DIG's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 3. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. 4. If required, as determined in DIAGNOSIS, above: reprogram the CCN using one of the following procedures, (based on scan tool use). 5. Was it determined in DIAGNOSIS, Step # 6 above, the CCN required updating? a. Yes >>> Proceed to appropriate CCN Module Reprogram Procedure Below, based on the scantool used. b. No >>> Repair is complete. NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 5289 NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. CCN MODULE REPROGRAM - USING wiTECH(R): 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id and "Password", then select "OK". 6. Select the "Next tab at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash" screen follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF position", remove the wiPOD(R) and battery charger from the vehicle. StarMOBILE(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident" flash file for statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 5290 b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step Se, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number (displayed at the end of the "Resident flash file for statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 5291 Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "Exhaust Filter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required - See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test Engine Control Module: All Technical Service Bulletins Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 5296 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 5301 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 5302 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness Technical Service Bulletin # K01 Date: 100510 Recall - ECM Update For OBD Readiness May 2010 Dealer Service Instructions for: California Emissions Recall K01 Reprogram ECM OBD Readiness Effective immediately all repairs on involved vehicles are to be performed according to this notification. Service Bulletin 18-038-09 is no longer applicable for the involved vehicles only. Models 2003 (DR) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETC) and a California emission control system (sales code NAE). 2006-2007 (DH/D1) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETH) and a California emission control system (sales code NAE). 2007 (DC) Dodge Ram Truck (3500 series cab chassis) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ) and a California emission control system (sales code NAE) built through January 5, 2007 (MDH010508). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process or GRS DealerCONNECT functions. Subject The Engine Control Module (ECM) on about 25,208 of the above vehicles may fail to accurately report diagnostic system information with some generic scan tools. This may cause the vehicle to be rejected or fail an Inspection/Maintenance Test (also known as a Smog Check). Repair The Engine Control Module (ECM) must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Part Number Description 04275086AB Authorized Modifications Label Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5307 The special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the label plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5308 To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: The DRBIII(R) must be used to perform this recall on 2003 Model Year (MY) vehicles. The 2003 MY procedure is found in Section D of the Service Procedure. Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall on 2006-2007 MY vehicles. This procedure must be performed with software release level 10.03 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5309 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's" button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section E. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5310 h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section E. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5311 e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 10. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 9. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 10. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 11. Continue with Section E. Install Authorized Modification Label. D. Reprogram the ECM Using DRBIII(R): The DealerCONNECT System, DRBIII(R) (Diagnostic Readout Box scan tool), CH7000A flash cable and CH7035B data cable are required to perform this repair. Do not attempt to perform the flash procedure using an outdated CH7000/CH7001 flash cable. NOTE: Whenever a controller is reprogrammed, the software in the DRBIII scan tool must be programmed with the latest revision level available. NOTE: If the flash process is interrupted or aborted, the flash should be restarted and then follow the directions on the DRBIII scan tool. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5312 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the DRBIII CH7000A flash cable from the DRBIII scan tool to the data link connector located inside the vehicle under the steering column. 3. Connect the CH7035B data cable from the DealerCONNECT machine to the MDS port on the DRBIII scan tool. 4. Place the vehicle's ignition key in the "RUN" position. 5. From the DealerCONNECT "WELCOME" screen, enter your "User I.D.," "Password" and "Dealer Code". 6. From the DealerCONNECT "HOME PAGE" select the "SERVICE" tab. 7. From the "SERVICE" tab screen select "TechTOOLS". 8. If the DRBIII scan tool does not "Auto Connect" select # 2 on the DRBIII key pad "Connect to TechCONNECT". 9. After the "Auto Connect" process is complete, select "READ PART NUMBER(S) FROM VEHICLE" on the TechCONNECT screen. 10. Continue following the TechCONNECT on-screen instructions. 11. Select the applicable update calibration. 12. Select the "DRBIII" button located at the bottom of the TechCONNECT monitor screen. 13. Select the "DOWNLOAD / UPDATE" button located next to the "DRBIII" button. NOTE: The system software will automatically download to the DRBIII scan tool. 14. After the software download to the DRBIII scan tool is complete, close the "DOWNLOAD / UPDATE PROGRESS" window. 15. Disconnect the DRBIII scan tool from the TechCONNECT CH7035B data cable. 16. Select # 1 "RETURN TO NORMAL MODE" on the DRBIII scan tool. 17. Use the following procedure to download the flash from the DRBIII scan tool to the vehicle. a. Select # 7 "VEHICLE FLASH" on the DRBIII scan tool. b. Follow the directions displayed on the DRBIII scan tool screen. c. After the reprogramming is complete, record the new module part number displayed on the DRBIII scan tool screen. d. Press the "PAGE BACK" button on the DRBIII scan tool. 18. Due to the ECM flash procedure, Diagnostic Trouble Codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS, ORC) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules, record the trouble codes, and erase the trouble codes using the following procedure: a. Turn the vehicle's ignition key to the "RUN" position. b. From the DRBIII scan tool Main Menu select # 1 "DRBIII Stand-Alone". c. From the DRBIII scan tool Stand-Alone menu select # 3 "Vehicle Module Scan". d. From the DRBIII scan tool Vehicle Module Scan menu select # 1 "1998 - 2005 Module Scan". e. Select "YES" on the DRBIII scan tool key pad to scan for DTC's. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5313 f. Follow the instructions on the DRBIII scan tool screen. g. Once the scanning process is complete, the DRBIII scan tool will display a list of all the modules. Modules on the list that have an asterisk next to them have DTC's that need to be cleared. h. Select the module that needs to have the DTC's cleared and follow the instructions on the DRBIII scan tool screen to clear the DTC's. i. Turn the vehicle's ignition key to the "OFF" position. NOTE: Erase any DTC's in the ECM only after all other modules have had their DTC's erased. 19. Disconnect the DRBIII scan tool from the vehicle. 20. Turn off the battery charger and disconnect it from the vehicle. 21. Continue with Section E. Install Authorized Modification Label. E. Install the Authorized Modifications Label: 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5314 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5319 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5320 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5321 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5322 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5327 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5328 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5329 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5330 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5331 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5332 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5333 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-030-07 > Apr > 07 > Engine Controls - Engine Off Idle Speed Limit Feature Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Off Idle Speed Limit Feature NUMBER: 18-030-07 GROUP: Vehicle Performance DATE: April 26, 2007 SUBJECT: Engine Off-Idle Speed Limit Feature To Protect Turbocharger When Vehicle Is Not Moving OVERVIEW: This bulletin involves a discussion regarding an engine control feature that limits engine off-idle speeds when the vehicle is not moving. MODELS: 2004 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 5.9L or a 6.7L Cummins turbo-diesel engine (sale codes: ETC, ETH, or ETJ). DISCUSSION: Dependent upon engine coolant temperature, the Engine Control Module (ECM) will temporarily delay (limit) the maximum engine speed when the vehicle is not moving. For automatic transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph, and when the transmission selector is in either the neutral or park position. For manual transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph. This ECM feature is used to protect the engine turbocharger. By temporarily limiting the vehicle engine speed, the shaft speed of the engine turbocharger is controlled to a low speed. This delay in maximum engine and turbo-charger shaft speed allows for sufficient oil lubrication to the turbocharger shaft bearings. Satisfactory oil lubrication of the turbocharger shaft bearings is important for long term turbocharger durability. The maximum engine speed for the 5.9L engine is temporarily limited to 1,600 RPM's when the above conditions are met. The 6.7L engine speed is temporarily limited to 1,200 RPM's when the above conditions are met. The length of time that the maximum engine speed is temporarily limited is dependent upon engine coolant temperature. Refer to the table to determine the amount of Time Delay. NOTE: The time delay values supplied in the table are an approximation and may vary per application. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Engine Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 5342 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 5343 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 5344 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 07-003-10 > Sep > 10 > Engine Controls - ECM Update for Fan Clutch Operation Engine Control Module: All Technical Service Bulletins Engine Controls - ECM Update for Fan Clutch Operation NUMBER: 07-003-10 GROUP: Cooling DATE: September 09, 2010 SUBJECT: High Coolant Temperatures On Vehicles Equipped With Snow Plows OVERVIEW: This bulletin provides information on how to program the Engine Control Module (ECM) to force the fan clutch to fully engage at all operating conditions MODELS: 2007 - 2010 DC/DM Ram 3500/4500/5500 Cab Chassis Trucks 2011 DD/DP Ram 3500/4500/5500 Cab Chassis Trucks NOTE: This bulletin applies to vehicles equipped with the 6.7L Cummins Diesel engine (Sales Code ETJ) DISCUSSION: Customers that operate their vehicle with a snowplow attached to the vehicle may cause the airflow passing through the radiator to be disrupted resulting in higher than normal engine temperatures The 6~7L Cummins ECM is equipped with software that can fully engage the fan clutch to allow an increase of airflow through the radiator Customers can initiate the fan clutch operation by performing the following button sequence NOTE: 2007 early 2009 models were not originally equipped with the fan clutch software however, recently released software does include this enhancement Ensure that the ECM software is at the latest level and if not, flash the ECM Refer to Service Bulletin 18-020-10 for additional information 1. Turn the ignition key to the run position or start the truck 2. Simultaneously press and release the Cruise Control "Cancel" button/lever and the "Exhaust Brake" button. Repeat this sequence four times within five seconds. The chime will sound twice as an audible indicator that the function is engaged 3. To disable the function, repeat the same procedure The chime will sound four times as an audible indicator that the function is disengaged NOTE: Customer's should be made aware that an increase in fan noise and a decrease in fuel economy may result when using this feature. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Systems/Exhaust Enhancements NUMBER: 18-020-10 GROUP: Vehicle Performance DATE: June 10, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-06, DATED DECEMBER 05, 2006 AND 18-001-09, DATED JANUARY 21, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. Either wiTECH OR StarMOBILE DESKTOP CLIENT can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. StarMOBILE® SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. SUBJECT: FLASH: Engine Systems And Exhaust Aftertreatment Systems Enhancements OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement based on customer use and mileage accumulation. This bulletin involves: ^ Selectively erasing and reprogramming the Engine Control Module (PCM), 2007 - 2010 MY. ^ Selectively erasing and reprogramming the Cab Compartment Node (CCN), 2007 & 2008 MY. ^ If CCN is updated; provide a Customer Information Sheet explaining the overhead display messages. ^ One of several software changes allows for "Net Zero" and "Net Reduction" which will cause noticeable changes in idle speeds. Customers should be informed of these changes. They are explained in DISCUSSION, Improvements that address erroneous MIL illumination for DTC P0106, P0191, P2262 and P2299 DTC's, (spelled out in DISCUSSION below). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. MODELS: 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) 2008 - 2010 (DM) Ram Truck (4500/5500 Cab Chassis) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). NOTE: For some 2007 MY vehicles, the ECM flash is addressed in Recall K01, Dated May, 2010. Where applicable. please use the Recall to update the ECM and this bulletin to update the CCN software. DISCUSSION: Cab chassis trucks equipped with a 6.7L Cummins diesel have a number of software improvements available. This latest Service Bulletin (SB) will include improvements to prevent erroneous Malfunction Indicator Lamp (MIL) illumination: ^ P000F - Fuel System Over Pressure Relief Valve Activated Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 5354 ^ P0087 - Fuel Rail Pressure Too Low ^ P0106 - Manifold Absolute Pressure Sensor Performance ^ P0191 - Fuel Rail Pressure Sensor Circuit Performance ^ P1011 - Fuel Pump Delivery Pressure Too Low ^ P2299 - Brake Pedal Position / Accelerator Pedal Position Incompatible ^ P2262 - Turbocharger Boost Pressure Not Detected - Mechanical Other updates will include the following operational and diagnostic improvements: 1. Stationary DeSoot is now available with this software. This feature works similar to pick up truck (DH/D1) models. 2. New DTC added for P2563 - Turbocharger Boost Control Position Sensor Performance. This DTC indicates diminished variable geometry turbocharger travel, which is resolved by replacing the turbocharger. Diagnosis and repair procedures for the DTC have been published in DTC-Based Diagnostics in TechConnect. 3. The latest PCM software includes a new extended idle feature to accommodate the extended idle times present in some duty cycles. This feature may help to reduce the accumulation of soot in the exhaust aftertreatment system when the engine is idling for an extended period of time. Briefly how this feature works: a. As needed, the engine enters an idling mode which dramatically reduces the rate of soot accumulation in the diesel particulate filter (called "Net Zero"). Further, under extended idle periods of 5 minutes or longer, the engine enters a mode which reduces the amount of soot accumulated in the diesel particulate filter (called "Net Reduction"). While in these modes, the idle speed increases to 900 RPM for a period of time. The idle speed may return to normal idle speed and then return to 900 RPM to repeat this cycle during very long idle periods. b. These modes occur automatically depending on the need to regenerate the DPF as long as the vehicle is not driven over 20 MPH or operated at high load. If the vehicle is driven over 20 MPH normal mobile desoot will occur automatically. 4. New scan tool driven fuel system diagnostic tests (same as previously released in the pick up) now available for cab chassis. DIAGNOSIS: 1. Using the scan tool, determine current software level of the PCM and CCN. Record on the repair order, for later use, the current PCM and CCN software level part numbers. Proceed to the next step. 2. Compare the current PCM software level part number with software available in the scantool. Determine if the current PCM software level part number, recorded in Step # 1, is programmable to a higher level. 3. Is the part number of the current PCM level software (recorded in Step # 1) at the latest level listed in the scan tool? a. If YES >> then the PCM DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. b. If NO >> then the PCM DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. 4. Is the vehicle a 2007 OR 2008 MY? a. Yes >>> Proceed to Step # 5. b. No >>> 2009 MY proceed to the REPAIR PROCEDURE as required. 5. Determine if the current CCN module level software part number, that was recorded earlier in Step # 1, is one of the following (or with a higher suffix): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 5355 a. 05172187AH (or higher) = 2007 DC (3500). b. 05172334AG (or higher) = 2008 DC (3500) / DM (3500/4500). c. 2009 & 2010 MY vehicles came equipped with proper CCN software. 6. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 5? a. If YES >>> then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. b. If NO >>> then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. PARTS REQUIRED: REPAIR PROCEDURE; ECM MODULE REPROGRAM: NOTE: The wiTECH diagnostic application is the preferred method for flashing ECU's. Help using the wiTECH diagnostic application for flashing an ECU is available by selecting "Help" then "Help Contents" at the top of the wiTECH diagnostic application window. NOTE: The wiTECH software level must be at release 10.04 or higher to perform this procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. If required, as determined in DIAGNOSIS, above: reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > 8E - Electronic Control Modules >MODULE, Engine Control, Diesel > Service Information > Standard Procedure > PCM/ECM Programming - DIESEL. After PCM reprogramming, the following must be performed: a. Clear any DIG's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 3. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. 4. If required, as determined in DIAGNOSIS, above: reprogram the CCN using one of the following procedures, (based on scan tool use). 5. Was it determined in DIAGNOSIS, Step # 6 above, the CCN required updating? a. Yes >>> Proceed to appropriate CCN Module Reprogram Procedure Below, based on the scantool used. b. No >>> Repair is complete. NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 5356 NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. CCN MODULE REPROGRAM - USING wiTECH(R): 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id and "Password", then select "OK". 6. Select the "Next tab at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash" screen follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF position", remove the wiPOD(R) and battery charger from the vehicle. StarMOBILE(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident" flash file for statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 5357 b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step Se, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number (displayed at the end of the "Resident flash file for statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 5358 Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "Exhaust Filter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required - See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test Engine Control Module: All Technical Service Bulletins Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 5363 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 5368 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 5369 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5374 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5375 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5376 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5377 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-030-07 > Apr > 07 > Engine Controls - Engine Off Idle Speed Limit Feature Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Off Idle Speed Limit Feature NUMBER: 18-030-07 GROUP: Vehicle Performance DATE: April 26, 2007 SUBJECT: Engine Off-Idle Speed Limit Feature To Protect Turbocharger When Vehicle Is Not Moving OVERVIEW: This bulletin involves a discussion regarding an engine control feature that limits engine off-idle speeds when the vehicle is not moving. MODELS: 2004 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 5.9L or a 6.7L Cummins turbo-diesel engine (sale codes: ETC, ETH, or ETJ). DISCUSSION: Dependent upon engine coolant temperature, the Engine Control Module (ECM) will temporarily delay (limit) the maximum engine speed when the vehicle is not moving. For automatic transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph, and when the transmission selector is in either the neutral or park position. For manual transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph. This ECM feature is used to protect the engine turbocharger. By temporarily limiting the vehicle engine speed, the shaft speed of the engine turbocharger is controlled to a low speed. This delay in maximum engine and turbo-charger shaft speed allows for sufficient oil lubrication to the turbocharger shaft bearings. Satisfactory oil lubrication of the turbocharger shaft bearings is important for long term turbocharger durability. The maximum engine speed for the 5.9L engine is temporarily limited to 1,600 RPM's when the above conditions are met. The 6.7L engine speed is temporarily limited to 1,200 RPM's when the above conditions are met. The length of time that the maximum engine speed is temporarily limited is dependent upon engine coolant temperature. Refer to the table to determine the amount of Time Delay. NOTE: The time delay values supplied in the table are an approximation and may vary per application. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Engine Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 5386 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 5387 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 5388 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness Technical Service Bulletin # K01 Date: 100510 Recall - ECM Update For OBD Readiness May 2010 Dealer Service Instructions for: California Emissions Recall K01 Reprogram ECM OBD Readiness Effective immediately all repairs on involved vehicles are to be performed according to this notification. Service Bulletin 18-038-09 is no longer applicable for the involved vehicles only. Models 2003 (DR) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETC) and a California emission control system (sales code NAE). 2006-2007 (DH/D1) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETH) and a California emission control system (sales code NAE). 2007 (DC) Dodge Ram Truck (3500 series cab chassis) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ) and a California emission control system (sales code NAE) built through January 5, 2007 (MDH010508). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process or GRS DealerCONNECT functions. Subject The Engine Control Module (ECM) on about 25,208 of the above vehicles may fail to accurately report diagnostic system information with some generic scan tools. This may cause the vehicle to be rejected or fail an Inspection/Maintenance Test (also known as a Smog Check). Repair The Engine Control Module (ECM) must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Part Number Description 04275086AB Authorized Modifications Label Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5394 The special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the label plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5395 To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: The DRBIII(R) must be used to perform this recall on 2003 Model Year (MY) vehicles. The 2003 MY procedure is found in Section D of the Service Procedure. Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall on 2006-2007 MY vehicles. This procedure must be performed with software release level 10.03 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5396 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's" button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section E. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5397 h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section E. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5398 e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 10. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 9. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 10. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 11. Continue with Section E. Install Authorized Modification Label. D. Reprogram the ECM Using DRBIII(R): The DealerCONNECT System, DRBIII(R) (Diagnostic Readout Box scan tool), CH7000A flash cable and CH7035B data cable are required to perform this repair. Do not attempt to perform the flash procedure using an outdated CH7000/CH7001 flash cable. NOTE: Whenever a controller is reprogrammed, the software in the DRBIII scan tool must be programmed with the latest revision level available. NOTE: If the flash process is interrupted or aborted, the flash should be restarted and then follow the directions on the DRBIII scan tool. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5399 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the DRBIII CH7000A flash cable from the DRBIII scan tool to the data link connector located inside the vehicle under the steering column. 3. Connect the CH7035B data cable from the DealerCONNECT machine to the MDS port on the DRBIII scan tool. 4. Place the vehicle's ignition key in the "RUN" position. 5. From the DealerCONNECT "WELCOME" screen, enter your "User I.D.," "Password" and "Dealer Code". 6. From the DealerCONNECT "HOME PAGE" select the "SERVICE" tab. 7. From the "SERVICE" tab screen select "TechTOOLS". 8. If the DRBIII scan tool does not "Auto Connect" select # 2 on the DRBIII key pad "Connect to TechCONNECT". 9. After the "Auto Connect" process is complete, select "READ PART NUMBER(S) FROM VEHICLE" on the TechCONNECT screen. 10. Continue following the TechCONNECT on-screen instructions. 11. Select the applicable update calibration. 12. Select the "DRBIII" button located at the bottom of the TechCONNECT monitor screen. 13. Select the "DOWNLOAD / UPDATE" button located next to the "DRBIII" button. NOTE: The system software will automatically download to the DRBIII scan tool. 14. After the software download to the DRBIII scan tool is complete, close the "DOWNLOAD / UPDATE PROGRESS" window. 15. Disconnect the DRBIII scan tool from the TechCONNECT CH7035B data cable. 16. Select # 1 "RETURN TO NORMAL MODE" on the DRBIII scan tool. 17. Use the following procedure to download the flash from the DRBIII scan tool to the vehicle. a. Select # 7 "VEHICLE FLASH" on the DRBIII scan tool. b. Follow the directions displayed on the DRBIII scan tool screen. c. After the reprogramming is complete, record the new module part number displayed on the DRBIII scan tool screen. d. Press the "PAGE BACK" button on the DRBIII scan tool. 18. Due to the ECM flash procedure, Diagnostic Trouble Codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS, ORC) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules, record the trouble codes, and erase the trouble codes using the following procedure: a. Turn the vehicle's ignition key to the "RUN" position. b. From the DRBIII scan tool Main Menu select # 1 "DRBIII Stand-Alone". c. From the DRBIII scan tool Stand-Alone menu select # 3 "Vehicle Module Scan". d. From the DRBIII scan tool Vehicle Module Scan menu select # 1 "1998 - 2005 Module Scan". e. Select "YES" on the DRBIII scan tool key pad to scan for DTC's. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5400 f. Follow the instructions on the DRBIII scan tool screen. g. Once the scanning process is complete, the DRBIII scan tool will display a list of all the modules. Modules on the list that have an asterisk next to them have DTC's that need to be cleared. h. Select the module that needs to have the DTC's cleared and follow the instructions on the DRBIII scan tool screen to clear the DTC's. i. Turn the vehicle's ignition key to the "OFF" position. NOTE: Erase any DTC's in the ECM only after all other modules have had their DTC's erased. 19. Disconnect the DRBIII scan tool from the vehicle. 20. Turn off the battery charger and disconnect it from the vehicle. 21. Continue with Section E. Install Authorized Modification Label. E. Install the Authorized Modifications Label: 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5401 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5406 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5407 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5408 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5409 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5410 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5411 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5412 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 5421 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 5422 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 5423 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control Engine Control Module: Locations Module-Engine Control Component ID: 203 Component : MODULE-ENGINE CONTROL Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (5.9L) Pin Description Circuit 1 WASTEGATE SOLENOID CONTROL K139 18DB 2 OIL PRESSURE SIGNAL G6 18VT/GY 3-4 CAN C BUS (+) D65 18WT/LG 5 CAN C BUS (-) D64 18WT/LB 6 FUEL CONTROL ACTUATOR RETURN K65 18BR/LB 7 GEN FIELD CONTROL K20 18BR/GY 8 TTVA MOTOR (+) K314 18TN/YL 9-10 - 11 WATER IN FUEL SENSOR GROUND K923 18BR/WT 12 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 13 INLET AIR TEMPERATURE SENSE K615 18VT/WT 14 - 15 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 16 INLET AIR PRESSURE SENSE K616 18BR/YL 17 ECT SIGNAL K2 18VT/OR 18 - 19 FUEL CONTROL ACTUATOR DRIVER K604 18BR/TN 20 TTVA MOTOR (-) K315 18TN/OR 21 FAN SPEED SENSOR GROUND K161 18BR/LB 22 CKP SIGNAL K24 18BR/LB 23 SENSOR GROUND K200 18BR/YL 24 CMP SIGNAL K44 18DB/GY 25 5 VOLT SUPPLY K668 18BR 26 - 27 5 VOLT SUPPLY K853 18DB/BR 28 - 29 SENSOR GROUND K690 18BR/YL 30 INJECTOR CONTROL NO. 1 K11 16BR/YL 31 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG 32 CMP SENSOR GROUND K944 18BK/GY Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5426 33 APPS NO. 1 RETURN K167 18BR/YL 34 FAN SPEED SENSOR SIGNAL N210 18DB/DG 35 - 36 INJECTOR CONTROL NO. 4 K14 16BR/TN 37 - 38 - 39 - 40 INJECTOR CONTROL NO. 3 K13 16TN 41 SENSOR GROUND K210 18DB/TN 42 5 VOLT SUPPLY K852 18BR/VT 43 BOOST PRESSURE SENSOR SIGNAL K37 18LB 44 - 45 - 46 INJECTOR CONTROL NO. 6 K58 16BR/VT 47 - 48 - 49 - 50 INJECTOR CONTROL NO. 2 K12 16BR/DB 51 - 52 CKP SENSOR GROUND K975 18BR/OR 53 FUEL RAIL SENSOR RETURN K915 18BR/WT 54 5 VOLT SUPPLY F855 18PK/YL 55 - 56 INJECTOR CONTROL NO. 5 K38 16GY 57 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 16TN/PK 58 - 59 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 16BR/LG 60 - Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5427 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5428 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5429 Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 2 EGR CONTROL NO. 1 K682 18DB/WT 3 EGR CONTROL NO. 2 K684 18DB/YL 4 EGR CONTROL NO. 3 K686 18GY/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5430 5 EGR SIGNAL NO. 2 K685 18DB 6-7 FAN SPEED SENSOR GROUND K161 18BR/LB 8-9 EGR BYPASS VALVE SIGNAL K670 18BR/LB 10 FUEL CONTROL ACTUATOR RETURN K366 18BR/LB 11 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 12 - 13 EGR AIRFLOW CONTROL VALVE MOTOR (-) K314 18BR 14 CRANKCASE SENSOR SIGNAL K926 18DB/GY 15 ECT SIGNAL K2 18VT/OR 16 - 17 EGR BYPASS STATUS K671 18BR/DB 18 FAN SPEED SENSOR SIGNAL N27 18DB/GY 19 BOOST PRESSURE SENSOR SIGNAL K37 18BR 20 INLET AIR PRESSURE SENSE K616 18BR/YL 21 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 22 SENSOR GROUND K971 18BR/PK 23 - 24 INLET AIR TEMPERATURE SENSE K615 18VT/WT 25 EGR SIGNAL NO. 1 K683 18DB/GY 26 5 VOLT SUPPLY K824 18DB/BR 27 EGR AIRFLOW CONTROL VALVE MOTOR (+) K158 18BR/YL 28 GEN SENSE A804 18RD 29 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 30 FUEL CONTROL ACTUATOR DRIVER K365 18DB/BR 31 CKP SIGNAL K24 18BR/LB 32 OIL PRESSURE SIGNAL G6 18VT/GY 33 ACTUATOR GROUND K972 18DB/TN 34 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG 35 EGR SIGNAL NO. 3 K687 18DB/LB 36 5 VOLT SUPPLY F855 18PK/YL 37 CMP SIGNAL K44 18DB/GY 38 ACTUATOR HIGH DATA LINK D130 18BR/VT 39 ACTUATOR LOW DATA LINK D131 18WT/LG 40 GEN FIELD CONTROL K20 18BR/GY 41 EGR TEMPERATURE SENSOR SIGNAL K935 18DB 42 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 43 TURBO SPEED SENSOR GROUND K541 18BR/VT 44 CKP SENSOR GROUND K925 18BR/OR 45 INJECTOR CONTROL NO. 6 K58 16BR/VT 46 INJECTOR CONTROL NO. 2 K12 16BR/DB 47 SENSOR GROUND K914 18BR/WT 48 SENSOR GROUND K916 18BR/OR 49 - 50 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG 51 INJECTOR HIGH SIDE DRIVER NO. 3 K613 16GY/BR 52 INJECTOR HIGH SIDE DRIVER NO. 2 K612 16YL/BR 53 INJECTOR HIGH SIDE DRIVER NO. 1 K611 16OR/BR 54 INJECTOR CONTROL NO. 4 K14 16BR/TN 55 INJECTOR CONTROL NO. 5 K38 16GY 56 INJECTOR CONTROL NO. 3 K13 16TN 57 INJECTOR CONTROL NO. 1 K11 16BR/YL 58 INJECTOR HIGH SIDE DRIVER NO. 6 K658 16LG/BR 59 INJECTOR HIGH SIDE DRIVER NO. 5 K638 16LB/BR 60 INJECTOR HIGH SIDE DRIVER NO. 4 K614 16WT/BR Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5431 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5432 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5433 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 50 Qualifier : (5.9L) Pin Description Circuit 1-2-3 APPS NO. 1 SIGNAL K23 18BR/WT 4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5434 5 TRANSMISSION CONTROL T515 18YL/DB 6 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 7 FUEL PUMP CONTROL K31 18BR 8-9 TRS T41 SIGNAL (P/N) T41 18YL/DB 10 - 11 - 12 - 13 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 18DG 14 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 15 3-4 SOLENOID CONTROL T9 18DG/TN 16 - 17 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 18 - 19 - 20 FUSED B(+) A209 16RD 21 GROUND Z902 16BK 22 - 23 5 VOLT SUPPLY F856 18YL/PK 24 SENSOR GROUND K900 18DB/DG 25 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 26 - 27 TTVA POSITION SENSOR SIGNAL K312 18OR 28 - 29 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR 30 FUSED B(+) A209 16RD 31 - 32 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 33 5 VOLT SUPPLY K854 18VT/BR 34 - 35 APPS NO. 2 SIGNAL K29 18WT/BR 36 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 37 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 38 - 39 - 40 FUSED B(+) A209 16RD 41 A/C CLUTCH CONTROL C13 18LB/OR 42 - 43 PWM FAN COIL SIGNAL K160 18BR/OR 44 OUTPUT SPEED SIGNAL T14 18DG/BR 45 SPEED SENSOR GROUND T13 18DG/VT 46 S/C SWITCH NO. 1 SIGNAL V37 18VT 47 BATT TEMP SIGNAL K25 18DB/VT 48 APPS NO. 2 RETURN K400 18BR/VT 49 GROUND Z902 16BK 50 GROUND Z902 16BK Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5435 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5436 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5437 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 CAN C BUS (+) D65 18WT/LG 2 FUEL PUMP CONTROL K31 18BR 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5438 5 EXHAUST BRAKE SWITCH SIGNAL G905 18BR/OR 6 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 7 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 8 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 9 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/OR 10 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 11 - 12 - 13 - 14 - 15 CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT T26 18DG/OR 16 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 17 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 18 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 19 - 20 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 21 CAN C BUS (-) D64 18WT/LB 22 APPS NO. 2 RETURN K400 18BR/VT 23 - 24 APPS NO. 2 SIGNAL K29 18WT/BR 25 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 26 5 VOLT SUPPLY K854 18VT/BR 27 5 VOLT SUPPLY K852 18BR/LB 28 APPS NO. 1 RETURN K167 18BR/DG 29 SENSOR GROUND K900 18DB/DG 30 BATT TEMP SIGNAL K25 18DB/VT 31 DIAGNOSTIC PORT HIGH DATA LINK D133 18WT/OR 32 - 33 S/C SWITCH RETURN V937 18VT/BR 34 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 35 APPS NO. 1 SIGNAL K23 18BR/WT 36 - 37 REMOTE THROTTLE SIGNAL K128 18DG/LG 38 - 39 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 40 S/C SWITCH NO. 1 SIGNAL V37 18VT 41 - 42 - 43 SMART POWER RELAY RETURN K348 18BR 44 A/C CLUTCH CONTROL C13 18LB 45 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 46 - 47 GROUND Z902 16BK 48 GROUND Z902 16BK 49 FUSED B(+) A209 16RD 50 FUSED B(+) A209 16RD 51 DIAGNOSTIC PORT LOW DATA LINK D132 18WT 52 - 53 - 54 EXHAUST BRAKE LAMP SIGNAL G904 18VT/DG 55 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 56 S/C SWITCH NO. 2 SIGNAL V38 18VT/OR 57 GROUND Z902 16BK 58 - 59 - 60 FUSED B(+) A209 16RD Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5439 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5440 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5441 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5442 Engine Control Module: Locations Module-Powertrain Control Component ID: 209 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Pin Description Circuit 123456- 789-10 11 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (RUN-START) F1 20PK/WT 13 14 15 16 17 18 - 19 SENSOR GROUND T160 20DG/WT 20 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 21 22 23 24 25 26 - 27 5 VOLT SUPPLY F856 20YL/PK 28 29 FUSED B(+) A918 20RD 30 IGNITION START T751 20YL 31 32 - Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5443 33 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 38 Component Location - 29 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5444 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 8 K98 18DB/YL 2-3 COIL CONTROL NO. 7 K97 18DB/YL 3 COIL CONTROL NO. 7 K97 18BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5445 4 INJECTOR CONTROL NO. 8 K28 18BR/LB 5 INJECTOR CONTROL NO. 7 K26 18BR/YL 6-7-8-9 GROUND Z130 16BK/BR 10 FUSED B(+) A918 16RD 11 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 13 - 14 - 15 - 16 - 17 - 18 GROUND Z131 16BK/DG 19 GROUND Z951 16BK/YL 20 OIL PRESSURE SIGNAL G6 16VT/GY 21 - 22 - 23 - 24 GEN SENSE A804 18RD/GY 25 - 27 5 VOLT SUPPLY F856 20YL/PK 28 MDS SOL CONTROL NO. 4 K452 20BR/LB 29 FUSED B(+) A918 16RD 30 IGNITION START T751 20YL 31 O2 1/2 SIGNAL K141 20DB/YL 32 O2 1/1 RETURN K902 20BR/DG 33 O2 2/2 SIGNAL K243 20BR 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 - 38 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5446 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5447 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 6 K10 18DB/OR 2 COIL CONTROL NO. 5 K16 18DB/YL 3 COIL CONTROL NO. 4 K15 18DB/GY 4 INJECTOR CONTROL NO. 6 K58 18BR/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5448 5 INJECTOR CONTROL NO. 5 K38 18BR/OR 6 ETC MOTOR (+) K447 20TN/YL 7 COIL CONTROL NO. 3 K18 18DB/OR 8 EGR SOL CONTROL K35 20DB/VT 9 COIL CONTROL NO. 2 K17 18DB/TN 10 COIL CONTROL NO. 1 K19 18DB/DG 11 INJECTOR CONTROL NO. 4 K14 18BR/TN 12 INJECTOR CONTROL NO. 3 K13 18BR/LB 13 INJECTOR CONTROL NO. 2 K12 18BR/DB 14 INJECTOR CONTROL NO. 1 K11 18BR/YL 15 TP SENSOR RETURN K922 20BR/DB 16 MDS SOL CONTROL NO. 6 K453 20BR/DG 17 O2 2/1 HEATER CONTROL K199 20BR/VT 18 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 19 GEN FIELD CONTROL K20 18BR/GY 20 ECT SIGNAL K2 20VT/OR 21 TP NO. 1 SIGNAL K22 20BR/OR 22 EGR SIGNAL K34 20DB/LG 23 MAP SIGNAL K1 20VT/BR 24 KNOCK SENSOR NO. 1 RETURN K942 20BR/LG 25 KNOCK SENSOR NO. 1 SIGNAL K42 20DB/YL 26 - 27 SENSOR GROUND K900 20DB/DG 28 TP NO. 2 SIGNAL K122 20BR/DG 28 IAC SIGNAL K961 20BR/VT 29 5 VOLT SUPPLY F855 20PK/YL 30 IAT SIGNAL K21 20DB/LG 31 O2 1/1 SIGNAL K41 20DB/LB 32 O2 1/2 RETURN K904 20DB/DG 33 O2 2/1 SIGNAL K43 20DB/LG 34 CMP SIGNAL K44 20DB/GY 35 CKP SIGNAL K24 20BR/LB 36 KNOCK SENSOR NO. 2 SIGNAL K242 20BR/WT 37 KNOCK SENSOR NO. 2 RETURN K924 20WT/BR 38 ETC MOTOR (-) K448 20TN/OR 38 IAC CONTROL K61 20VT/GY Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5449 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5450 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1-2-3 ASD CONTROL K51 20BR/WT 4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5451 5 S/C VENT SOL CONTROL V35 20VT/OR 5 MDS SOL CONTROL NO. 7 K454 20BR/OR 6 MDS SOL CONTROL NO. 1 K451 20BR/WT 7 SPEED CONTROL SUPPLY V32 20VT/YL 8-9 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 10 O2 2/2 HEATER CONTROL K399 18BR/GY 11 A/C CLUTCH CONTROL C13 20LB/OR 12 S/C VACUUM SOL CONTROL V36 20VT/YL 13 - 14 BRAKE SWITCH NO. 2 SIGNAL V32 20VT/YL 15 S/C SWITCH RETURN V937 20VT/BR 16 APPS NO. 1 RETURN K167 20BR/YL 17 APPS NO. 2 RETURN K400 20BR/VT 18 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 19 ASD CONTROL OUTPUT K342 16BR/WT 20 EVAP PURGE SOL CONTROL K52 20DB/WT 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 PTO SENSE G113 20VT 22 PTO SENSE G113 18PK/YL 23 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT 24 - 25 APPS NO. 1 SIGNAL K23 20BR/WT 26 - 27 - 28 ASD CONTROL OUTPUT K342 16BR/WT 29 EVAP PURGE SOL SIGNAL K70 20DB/BR 30 P/S SWITCH SIGNAL K66 20DB/WT 31 - 32 - 33 OIL TEMPERATURE SIGNAL G24 20VT/BR 34 S/C SWITCH NO. 1 SIGNAL V37 20VT 35 ESM SIGNAL K107 20VT/WT 36 APPS NO. 2 SIGNAL K29 20WT/BR 37 FUEL PUMP CONTROL K31 20BR 38 STARTER SOLENOID CONTROL T752 20DG/OR Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5452 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5453 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Description Circuit 1 SENSOR GROUND T160 20YL/GY 2 4C CONTROL T259 20YL/DG 34 MS CONTROL T140 20YL/GY Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5454 56 2C CONTROL T219 20YL/LG 78 UD CONTROL T59 20YL/LB 910 L/R CONTROL T20 20DG/BK 11 LINE PRESSURE CONTROL T118 20DG 12 GROUND Z133 18BK/LG 13 GROUND Z133 18BK/LG 14 GROUND Z133 18BK/LG 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 24 25 26 TRS T2 SIGNAL T4 20DG/LB 27 TRS T41 SIGNAL (P/N) T41 20YL/DB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5455 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5456 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 OD SOLENOID CONTROL T60 20YL/GY 2 4C CONTROL T259 20YL/DG 2 UD CONTROL T59 20YL/LB 3-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5457 4 MS CONTROL T140 20YL/GY 5-6 2C CONTROL T219 20YL/LG 6 2-4 SOLENOID CONTROL T19 18YL/DB 7-8 UD CONTROL T59 20YL/LB 9-10 L/R CONTROL T20 20DG/WT 11 PRESSURE CONTROL SOLENOID CONTROL T118 20DG 12 GROUND Z908 18BK 13 GROUND Z977 18BK 14 GROUND Z904 18BK 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 - 24 - 25 - 26 TRS T2 SIGNAL T4 20DG/LB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 30 2-4 PRESSURE SWITCH SENSE T47 18YL/DG 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5458 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5459 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5462 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5463 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5464 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5465 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5466 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5467 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5468 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5469 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5470 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5471 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5472 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5473 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5474 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5475 Engine Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5476 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5477 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5478 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5479 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5480 Engine Control Module: Connector Views Module-Engine Control Component ID: 203 Component : MODULE-ENGINE CONTROL Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (5.9L) Pin Description Circuit 1 WASTEGATE SOLENOID CONTROL K139 18DB 2 OIL PRESSURE SIGNAL G6 18VT/GY 3-4 CAN C BUS (+) D65 18WT/LG 5 CAN C BUS (-) D64 18WT/LB 6 FUEL CONTROL ACTUATOR RETURN K65 18BR/LB 7 GEN FIELD CONTROL K20 18BR/GY 8 TTVA MOTOR (+) K314 18TN/YL 9-10 - 11 WATER IN FUEL SENSOR GROUND K923 18BR/WT 12 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 13 INLET AIR TEMPERATURE SENSE K615 18VT/WT 14 - 15 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 16 INLET AIR PRESSURE SENSE K616 18BR/YL 17 ECT SIGNAL K2 18VT/OR 18 - 19 FUEL CONTROL ACTUATOR DRIVER K604 18BR/TN 20 TTVA MOTOR (-) K315 18TN/OR 21 FAN SPEED SENSOR GROUND K161 18BR/LB 22 CKP SIGNAL K24 18BR/LB 23 SENSOR GROUND K200 18BR/YL 24 CMP SIGNAL K44 18DB/GY 25 5 VOLT SUPPLY K668 18BR 26 - 27 5 VOLT SUPPLY K853 18DB/BR 28 - 29 SENSOR GROUND K690 18BR/YL 30 INJECTOR CONTROL NO. 1 K11 16BR/YL 31 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5481 32 CMP SENSOR GROUND K944 18BK/GY 33 APPS NO. 1 RETURN K167 18BR/YL 34 FAN SPEED SENSOR SIGNAL N210 18DB/DG 35 - 36 INJECTOR CONTROL NO. 4 K14 16BR/TN 37 - 38 - 39 - 40 INJECTOR CONTROL NO. 3 K13 16TN 41 SENSOR GROUND K210 18DB/TN 42 5 VOLT SUPPLY K852 18BR/VT 43 BOOST PRESSURE SENSOR SIGNAL K37 18LB 44 - 45 - 46 INJECTOR CONTROL NO. 6 K58 16BR/VT 47 - 48 - 49 - 50 INJECTOR CONTROL NO. 2 K12 16BR/DB 51 - 52 CKP SENSOR GROUND K975 18BR/OR 53 FUEL RAIL SENSOR RETURN K915 18BR/WT 54 5 VOLT SUPPLY F855 18PK/YL 55 - 56 INJECTOR CONTROL NO. 5 K38 16GY 57 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 16TN/PK 58 - 59 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 16BR/LG 60 - Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5482 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5483 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5484 Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 2 EGR CONTROL NO. 1 K682 18DB/WT 3 EGR CONTROL NO. 2 K684 18DB/YL 4 EGR CONTROL NO. 3 K686 18GY/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5485 5 EGR SIGNAL NO. 2 K685 18DB 6-7 FAN SPEED SENSOR GROUND K161 18BR/LB 8-9 EGR BYPASS VALVE SIGNAL K670 18BR/LB 10 FUEL CONTROL ACTUATOR RETURN K366 18BR/LB 11 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 12 - 13 EGR AIRFLOW CONTROL VALVE MOTOR (-) K314 18BR 14 CRANKCASE SENSOR SIGNAL K926 18DB/GY 15 ECT SIGNAL K2 18VT/OR 16 - 17 EGR BYPASS STATUS K671 18BR/DB 18 FAN SPEED SENSOR SIGNAL N27 18DB/GY 19 BOOST PRESSURE SENSOR SIGNAL K37 18BR 20 INLET AIR PRESSURE SENSE K616 18BR/YL 21 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 22 SENSOR GROUND K971 18BR/PK 23 - 24 INLET AIR TEMPERATURE SENSE K615 18VT/WT 25 EGR SIGNAL NO. 1 K683 18DB/GY 26 5 VOLT SUPPLY K824 18DB/BR 27 EGR AIRFLOW CONTROL VALVE MOTOR (+) K158 18BR/YL 28 GEN SENSE A804 18RD 29 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 30 FUEL CONTROL ACTUATOR DRIVER K365 18DB/BR 31 CKP SIGNAL K24 18BR/LB 32 OIL PRESSURE SIGNAL G6 18VT/GY 33 ACTUATOR GROUND K972 18DB/TN 34 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG 35 EGR SIGNAL NO. 3 K687 18DB/LB 36 5 VOLT SUPPLY F855 18PK/YL 37 CMP SIGNAL K44 18DB/GY 38 ACTUATOR HIGH DATA LINK D130 18BR/VT 39 ACTUATOR LOW DATA LINK D131 18WT/LG 40 GEN FIELD CONTROL K20 18BR/GY 41 EGR TEMPERATURE SENSOR SIGNAL K935 18DB 42 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 43 TURBO SPEED SENSOR GROUND K541 18BR/VT 44 CKP SENSOR GROUND K925 18BR/OR 45 INJECTOR CONTROL NO. 6 K58 16BR/VT 46 INJECTOR CONTROL NO. 2 K12 16BR/DB 47 SENSOR GROUND K914 18BR/WT 48 SENSOR GROUND K916 18BR/OR 49 - 50 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG 51 INJECTOR HIGH SIDE DRIVER NO. 3 K613 16GY/BR 52 INJECTOR HIGH SIDE DRIVER NO. 2 K612 16YL/BR 53 INJECTOR HIGH SIDE DRIVER NO. 1 K611 16OR/BR 54 INJECTOR CONTROL NO. 4 K14 16BR/TN 55 INJECTOR CONTROL NO. 5 K38 16GY 56 INJECTOR CONTROL NO. 3 K13 16TN 57 INJECTOR CONTROL NO. 1 K11 16BR/YL 58 INJECTOR HIGH SIDE DRIVER NO. 6 K658 16LG/BR 59 INJECTOR HIGH SIDE DRIVER NO. 5 K638 16LB/BR 60 INJECTOR HIGH SIDE DRIVER NO. 4 K614 16WT/BR Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5486 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5487 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5488 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 50 Qualifier : (5.9L) Pin Description Circuit 1-2-3 APPS NO. 1 SIGNAL K23 18BR/WT 4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5489 5 TRANSMISSION CONTROL T515 18YL/DB 6 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 7 FUEL PUMP CONTROL K31 18BR 8-9 TRS T41 SIGNAL (P/N) T41 18YL/DB 10 - 11 - 12 - 13 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 18DG 14 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 15 3-4 SOLENOID CONTROL T9 18DG/TN 16 - 17 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 18 - 19 - 20 FUSED B(+) A209 16RD 21 GROUND Z902 16BK 22 - 23 5 VOLT SUPPLY F856 18YL/PK 24 SENSOR GROUND K900 18DB/DG 25 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 26 - 27 TTVA POSITION SENSOR SIGNAL K312 18OR 28 - 29 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR 30 FUSED B(+) A209 16RD 31 - 32 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 33 5 VOLT SUPPLY K854 18VT/BR 34 - 35 APPS NO. 2 SIGNAL K29 18WT/BR 36 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 37 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 38 - 39 - 40 FUSED B(+) A209 16RD 41 A/C CLUTCH CONTROL C13 18LB/OR 42 - 43 PWM FAN COIL SIGNAL K160 18BR/OR 44 OUTPUT SPEED SIGNAL T14 18DG/BR 45 SPEED SENSOR GROUND T13 18DG/VT 46 S/C SWITCH NO. 1 SIGNAL V37 18VT 47 BATT TEMP SIGNAL K25 18DB/VT 48 APPS NO. 2 RETURN K400 18BR/VT 49 GROUND Z902 16BK 50 GROUND Z902 16BK Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5490 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5491 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5492 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 CAN C BUS (+) D65 18WT/LG 2 FUEL PUMP CONTROL K31 18BR 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5493 5 EXHAUST BRAKE SWITCH SIGNAL G905 18BR/OR 6 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 7 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 8 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 9 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/OR 10 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 11 - 12 - 13 - 14 - 15 CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT T26 18DG/OR 16 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 17 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 18 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 19 - 20 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 21 CAN C BUS (-) D64 18WT/LB 22 APPS NO. 2 RETURN K400 18BR/VT 23 - 24 APPS NO. 2 SIGNAL K29 18WT/BR 25 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 26 5 VOLT SUPPLY K854 18VT/BR 27 5 VOLT SUPPLY K852 18BR/LB 28 APPS NO. 1 RETURN K167 18BR/DG 29 SENSOR GROUND K900 18DB/DG 30 BATT TEMP SIGNAL K25 18DB/VT 31 DIAGNOSTIC PORT HIGH DATA LINK D133 18WT/OR 32 - 33 S/C SWITCH RETURN V937 18VT/BR 34 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 35 APPS NO. 1 SIGNAL K23 18BR/WT 36 - 37 REMOTE THROTTLE SIGNAL K128 18DG/LG 38 - 39 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 40 S/C SWITCH NO. 1 SIGNAL V37 18VT 41 - 42 - 43 SMART POWER RELAY RETURN K348 18BR 44 A/C CLUTCH CONTROL C13 18LB 45 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 46 - 47 GROUND Z902 16BK 48 GROUND Z902 16BK 49 FUSED B(+) A209 16RD 50 FUSED B(+) A209 16RD 51 DIAGNOSTIC PORT LOW DATA LINK D132 18WT 52 - 53 - 54 EXHAUST BRAKE LAMP SIGNAL G904 18VT/DG 55 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 56 S/C SWITCH NO. 2 SIGNAL V38 18VT/OR 57 GROUND Z902 16BK 58 - 59 - 60 FUSED B(+) A209 16RD Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5494 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5495 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5496 Module-Powertrain Control Component ID: 209 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5497 Pin Description Circuit 123456789-10 11 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (RUN-START) F1 20PK/WT 13 14 15 16 17 18 - 19 SENSOR GROUND T160 20DG/WT 20 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 21 22 23 24 25 26 - 27 5 VOLT SUPPLY F856 20YL/PK 28 29 FUSED B(+) A918 20RD 30 IGNITION START T751 20YL 31 32 33 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 38 Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5498 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5499 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 8 K98 18DB/YL 2-3 COIL CONTROL NO. 7 K97 18DB/YL 3 COIL CONTROL NO. 7 K97 18BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5500 4 INJECTOR CONTROL NO. 8 K28 18BR/LB 5 INJECTOR CONTROL NO. 7 K26 18BR/YL 6-7-8-9 GROUND Z130 16BK/BR 10 FUSED B(+) A918 16RD 11 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 13 - 14 - 15 - 16 - 17 - 18 GROUND Z131 16BK/DG 19 GROUND Z951 16BK/YL 20 OIL PRESSURE SIGNAL G6 16VT/GY 21 - 22 - 23 - 24 GEN SENSE A804 18RD/GY 25 - 27 5 VOLT SUPPLY F856 20YL/PK 28 MDS SOL CONTROL NO. 4 K452 20BR/LB 29 FUSED B(+) A918 16RD 30 IGNITION START T751 20YL 31 O2 1/2 SIGNAL K141 20DB/YL 32 O2 1/1 RETURN K902 20BR/DG 33 O2 2/2 SIGNAL K243 20BR 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 - 38 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5501 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5502 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 6 K10 18DB/OR 2 COIL CONTROL NO. 5 K16 18DB/YL 3 COIL CONTROL NO. 4 K15 18DB/GY 4 INJECTOR CONTROL NO. 6 K58 18BR/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5503 5 INJECTOR CONTROL NO. 5 K38 18BR/OR 6 ETC MOTOR (+) K447 20TN/YL 7 COIL CONTROL NO. 3 K18 18DB/OR 8 EGR SOL CONTROL K35 20DB/VT 9 COIL CONTROL NO. 2 K17 18DB/TN 10 COIL CONTROL NO. 1 K19 18DB/DG 11 INJECTOR CONTROL NO. 4 K14 18BR/TN 12 INJECTOR CONTROL NO. 3 K13 18BR/LB 13 INJECTOR CONTROL NO. 2 K12 18BR/DB 14 INJECTOR CONTROL NO. 1 K11 18BR/YL 15 TP SENSOR RETURN K922 20BR/DB 16 MDS SOL CONTROL NO. 6 K453 20BR/DG 17 O2 2/1 HEATER CONTROL K199 20BR/VT 18 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 19 GEN FIELD CONTROL K20 18BR/GY 20 ECT SIGNAL K2 20VT/OR 21 TP NO. 1 SIGNAL K22 20BR/OR 22 EGR SIGNAL K34 20DB/LG 23 MAP SIGNAL K1 20VT/BR 24 KNOCK SENSOR NO. 1 RETURN K942 20BR/LG 25 KNOCK SENSOR NO. 1 SIGNAL K42 20DB/YL 26 - 27 SENSOR GROUND K900 20DB/DG 28 TP NO. 2 SIGNAL K122 20BR/DG 28 IAC SIGNAL K961 20BR/VT 29 5 VOLT SUPPLY F855 20PK/YL 30 IAT SIGNAL K21 20DB/LG 31 O2 1/1 SIGNAL K41 20DB/LB 32 O2 1/2 RETURN K904 20DB/DG 33 O2 2/1 SIGNAL K43 20DB/LG 34 CMP SIGNAL K44 20DB/GY 35 CKP SIGNAL K24 20BR/LB 36 KNOCK SENSOR NO. 2 SIGNAL K242 20BR/WT 37 KNOCK SENSOR NO. 2 RETURN K924 20WT/BR 38 ETC MOTOR (-) K448 20TN/OR 38 IAC CONTROL K61 20VT/GY Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5504 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5505 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1-2-3 ASD CONTROL K51 20BR/WT 4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5506 5 S/C VENT SOL CONTROL V35 20VT/OR 5 MDS SOL CONTROL NO. 7 K454 20BR/OR 6 MDS SOL CONTROL NO. 1 K451 20BR/WT 7 SPEED CONTROL SUPPLY V32 20VT/YL 8-9 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 10 O2 2/2 HEATER CONTROL K399 18BR/GY 11 A/C CLUTCH CONTROL C13 20LB/OR 12 S/C VACUUM SOL CONTROL V36 20VT/YL 13 - 14 BRAKE SWITCH NO. 2 SIGNAL V32 20VT/YL 15 S/C SWITCH RETURN V937 20VT/BR 16 APPS NO. 1 RETURN K167 20BR/YL 17 APPS NO. 2 RETURN K400 20BR/VT 18 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 19 ASD CONTROL OUTPUT K342 16BR/WT 20 EVAP PURGE SOL CONTROL K52 20DB/WT 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 PTO SENSE G113 20VT 22 PTO SENSE G113 18PK/YL 23 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT 24 - 25 APPS NO. 1 SIGNAL K23 20BR/WT 26 - 27 - 28 ASD CONTROL OUTPUT K342 16BR/WT 29 EVAP PURGE SOL SIGNAL K70 20DB/BR 30 P/S SWITCH SIGNAL K66 20DB/WT 31 - 32 - 33 OIL TEMPERATURE SIGNAL G24 20VT/BR 34 S/C SWITCH NO. 1 SIGNAL V37 20VT 35 ESM SIGNAL K107 20VT/WT 36 APPS NO. 2 SIGNAL K29 20WT/BR 37 FUEL PUMP CONTROL K31 20BR 38 STARTER SOLENOID CONTROL T752 20DG/OR Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5507 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5508 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Description Circuit 1 SENSOR GROUND T160 20YL/GY 2 4C CONTROL T259 20YL/DG 34 MS CONTROL T140 20YL/GY Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5509 56 2C CONTROL T219 20YL/LG 78 UD CONTROL T59 20YL/LB 910 L/R CONTROL T20 20DG/BK 11 LINE PRESSURE CONTROL T118 20DG 12 GROUND Z133 18BK/LG 13 GROUND Z133 18BK/LG 14 GROUND Z133 18BK/LG 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 24 25 26 TRS T2 SIGNAL T4 20DG/LB 27 TRS T41 SIGNAL (P/N) T41 20YL/DB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5510 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5511 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 OD SOLENOID CONTROL T60 20YL/GY 2 4C CONTROL T259 20YL/DG 2 UD CONTROL T59 20YL/LB 3-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5512 4 MS CONTROL T140 20YL/GY 5-6 2C CONTROL T219 20YL/LG 6 2-4 SOLENOID CONTROL T19 18YL/DB 7-8 UD CONTROL T59 20YL/LB 9-10 L/R CONTROL T20 20DG/WT 11 PRESSURE CONTROL SOLENOID CONTROL T118 20DG 12 GROUND Z908 18BK 13 GROUND Z977 18BK 14 GROUND Z904 18BK 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 - 24 - 25 - 26 TRS T2 SIGNAL T4 20DG/LB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 30 2-4 PRESSURE SWITCH SENSE T47 18YL/DG 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5513 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5514 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description Engine Control Module: Description and Operation Description DESCRIPTION CUMMINS FUEL SYSTEM COMPONENTS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 5517 The Engine Control Module (ECM) for the 5.9L diesel engine (16) is bolted to the left side of the engine below the intake manifold. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 5518 Engine Control Module: Description and Operation Operation OPERATION The main function of the Engine Control Module (ECM) is to electrically control the fuel system. The ECM also controls certain transmission and other functions previously controlled by the Powertrain Control Module (PCM). The ECM can adapt its programming to meet changing operating conditions. The ECM receives input signals from various switches and sensors. Based on these inputs, the ECM regulates various engine and vehicle operations through different system components. These components are referred to as ECM Outputs. The sensors and switches that provide inputs to the ECM are considered ECM Inputs. NOTE: ECM Inputs: - Accelerator Pedal Position Sensor (APPS) Signals #1 and #2 - AC system pressure - Auto shutdown (ASD) sense - Battery temperature - Battery temperature sensor - Battery voltage - Brake switch - Camshaft Position Sensor (CMP) - Crankshaft Position Sensor (CKP) - Data link connection for a scan tool - Engine Coolant Temperature (ECT) sensor - EATX module (if equipped) - Fuel level - Fuel pressure sensor - Fan speed (engine cooling fan) - Generator (battery voltage) output - Governor pressure (Auto. trans.) - Ground circuits - Inlet air temperature sensor/pressure sensor - Intake air temperature sensor/MAP sensor - CAN C BUS (+) circuits - CAN C BUS (-) circuits - Key switch (ignition) - Oil Pressure switch - Overdrive switch (automatic transmission only) - Park/neutral switch (auto. trans. only) - Power ground - SCI datalink bus (+) circuits - SCI datalink bus (-) circuits - Sensor return - Signal ground - Speed control multiplexed single wire input - Transfer case switch (4WD range position) - Transmission governor psi (automatic transmission only) - Transmission OSS (automatic transmission only) - Transmission oil pressure (automatic transmission only) - Transmission oil temperature (automatic transmission only) - Transmission throttle valve position (automatic transmission only) - Vehicle speed signal - Water-In-Fuel (WIF) sensor NOTE: ECM Outputs: After inputs are received by the ECM, certain sensors, switches and components are controlled or regulated by the ECM. These are considered ECM Outputs. These outputs are for: - A/C clutch relay - Auto shutdown (ASD) relay - Data link connection for diagnostic scan tool - Fan clutch PWM Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 5519 - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel control actuator - Fuel injector driver circuits - Fuel transfer (lift) pump - Generator field driver (-) - Generator field driver (+) - Governor pressure (VFS solenoid) - Intake manifold air heater relays #1 and #2 control circuits - CAN C BUS (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oil pressure switch/warning lamp (databus) - Overdrive/3-4 shift solenoid (automatic transmission only) - SC source - SCI datalink bus (+) circuits - SCI datalink bus (-) circuits - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - TCC solenoid (automatic transmission only) - Transmission battery relay (automatic transmission only) - Transmission throttle valve actuator (automatic transmission only) - Transmission governor solenoid (automatic transmission only) - Wait-to-start warning lamp (databus) - Turbo wastegate solenoid - Water-In-Fuel (WIF) warning lamp (databus) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming Engine Control Module: Testing and Inspection PCM/ECM Programming PCM/ECM REPROGRAMMING MODULE REPROGRAMING Replacement PCM's will require programming utilizing the StarSCAN(R) or equivalent. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. SPECIAL TOOLS/EQUIPMENT OR EQUIVALENT REQUIRED: **REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The StarSCAN(R) or equivalent diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) or equivalent for your dealership's network. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9410 StarSCAN(R) or equivalent ethernet cable to the StarSCAN(R) or equivalent and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 4. Power ON the StarSCAN(R) or equivalent. 5. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. 6. Replace the PCM with the appropriate Generic PCM. 7. Program the PCM as follows: a. Using the StarSCAN(R) or equivalent at the "Home" screen, Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File". Follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 5522 f. Highlight the appropriate calibration based on the part number recorded in Step 5. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. 8. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 9. b. No >> go to STEP 10. 9. Program the PCM to the Wireless Control Module (WCM). a. Highlight the WCM. b. Select "Misc. Function". c. Highlight "PCM Replaced". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step. f. When complete proceed to STEP 11. 10. Program the VIN into the PCM. a. Scroll through the list of controllers and highlight the PCM. b. Select "Misc. Function". c. Highlight "Check PCM VIN". d. Select "Start". e. Follow the on screen instructions. Select "Next" after each step . When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 11. Is the vehicle equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 13. b. No >> go to STEP 12. 12. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select ECU View b. Scroll through the list of controllers and highlight the PCM. c. Select Misc. Function. d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select Next after each step . Select Finish after completing the last step. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the Home screen select System View. Then select All DTCs. Press Clear All Stored DTCs if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label . REPAIR PROCEDURE USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 5523 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 3. Power ON the StarSCAN(R) or equivalent. 4. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. 5. Replace the PCM with the appropriate Generic PCM. 6. Insert the StarSCAN(R) or equivalent Software Update CD into the Techconnect or equivalent PC. The StarSCAN(R) or equivalent Software Update CD will start automatically. Select "Download Flash Updates". 7. At the "Select a method for looking up controller flash updates." screen: a. Select "Enter part number". Enter the "Part Number" recorded in STEP 4 when prompted to do so. b. Using the mouse highlight the appropriate "Calibration". Select "Next". c. Follow the on screen instructions. d. When completed, proceed to STEP 8. 8. With the StarSCAN(R) or equivalent powered OFF, connect the USB Key and Gender Changer to the StarSCAN(R) or equivalent USB port . 9. Connect the StarSCAN(R) or equivalent to the vehicle (if not already connected). 10. Power ON the StarSCAN(R) or equivalent. 11. Download the flash file from the USB key to the StarSCAN(R) or equivalent. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "Flash Download", then select "Retrieve files from the USB storage device" b. Highlight the appropriate calibration. Select "Download to Scan Tool" c. When the download is complete, select "Close" and "Back". 12. Reprogram the ECU. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View". b. Select More Options". c. Select "ECU Flash". d. Highlight the appropriate calibration. e. Select "Update Controller". Follow the on screen instructions. f. When the update is complete, select "OK". g. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 5524 13. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 14. b. No >> go to STEP 15. 14. Program the PCM to the Wireless Control Module (WCM). Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the WCM. c. Select "Misc. Function". d. Highlight "PCM Replaced". e. Select "Start". f. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step. g. When complete proceed to STEP 16. 15. Program the VIN into the PCM. a. Scroll through the list of controllers and highlight the PCM. b. Select "Misc. Function". c. Highlight "Check PCM VIN". d. Select "Start". e. Follow the on screen instructions. Select "Next" after each step . When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 16. Is the vehicle equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 18. b. No >> go to STEP 17. 17. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the PCM. c. Select "Misc. Function". d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "ECU View" from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 18. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label . Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 5525 Engine Control Module: Testing and Inspection SKREEM Programming SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: 1. Program the new PCM/ECM. 2. Program the new SKREEM/WCM. 3. Replace all ignition keys and program them into the new SKREEM/WCM. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Be certain to enter the correct country code for the SKREEM/WCM. If the incorrect country code is programmed into the SKREEM, it cannot be changed and the SKREEM must be replaced. NOTE: In addition, the SKREEM/WCM must be configured for certain optional equipment in the vehicle, including Tire Pressure Monitor (TPM), Remote Keyless Entry (RKE) and Remote Start. Follow the programming steps outlined in the diagnostic scan tool under MISCELLANEOUS FUNCTIONS for the WCM/WIRELESS CONTROL MODULE menu item as appropriate. NOTE: A replacement SKREEM/WCM is supplied with TPM enabled by default; therefore, if the vehicle is not equipped with TPM, the ElectroMechanical Instrument Cluster (EMIC) will incorrectly learn that the vehicle has TPM after the replacement SKREEM is installed. The TPM indicator in the EMIC will illuminate to show a TPM fault condition after TPM has been disabled in the SKREEM. The EMIC must unlearn TPM to correct this false TPM indication. Follow the programming steps outlined in the diagnostic scan tool for CLEAR LEARNED FEATURES under MISCELLANEOUS FUNCTIONS for the INSTRUMENT CLUSTER menu item as appropriate. NOTE: If the PCM/ECM and the SKREEM/WCM are replaced at the same time, all vehicle ignition keys will need to be replaced and the new keys programmed into the new SKREEM/WCM. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 5526 Engine Control Module: Testing and Inspection Programming The SKREEM/WCM Using The Scan Tool STANDARD PROCEDURE - PROGRAMMING THE SKREEM/WCM USING THE SCAN TOOL CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the scan tool. CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal Engine Control Module: Service and Repair Removal 6.7L DIESEL The Engine Control Module (ECM) (5) is located on the left side of the engine. A support bracket mounts to the block with four capscrews and vibration isolators. A ground wire is fastened to the bracket. The other end of the wire is fastened to the engine block. 1. Record any Diagnostic Trouble Codes (DTC's) found in the ECM. To avoid possible voltage spike damage to the ECM, ignition key must be off, and both negative battery cables must be disconnected before unplugging ECM connectors. 2. Disconnect both negative battery cables at both batteries. Access to the ECM is easier by working through the left front wheel opening. 3. Remove left front wheel. 4. Remove plastic left front fender splash shield. 5. Remove electrical connector bolts at ECM. Note: As each bolt is being removed, very carefully remove connectors from the ECM. 6. Remove three ECM mounting bolts (6) and remove ECM from engine. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 5529 Engine Control Module: Service and Repair Installation 6.7L DIESEL Do not apply paint to ECM or a poor ground will result. 1. Position ECM (5) to the ECM support bracket and install mounting bolts. Tighten bolts to 24 Nm (18 ft. lbs.). 2. Check pins in electrical connectors for corrosion, damage or dirt intrusion. Also check all pins for being bent. Repair as necessary. Damaged, dirty, bent or corroded pins could result in poor conductivity, causing intermittent electrical issues or DTC's. 3. Clean pins in electrical connectors with an electrical contact cleaner. 4. Install connectors to ECM. Tighten connector bolts to 3 Nm (27 in. lbs.). 5. Install splash shield. 6. Install left front wheel. 7. Connect both negative battery cables. 8. Use a diagnostic scan tool to erase any Diagnostic Trouble Codes (DTC's) from ECM. FUEL INJECTOR ID CORRECTION CODES: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 5530 Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector (1) and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Engine Control Module (ECM) using a diagnostic scan tool. In addition, if a new ECM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new ECM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 5535 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 5536 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 5537 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 5538 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 5539 Component Location - 25 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 5540 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 5543 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 5544 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 5545 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 5546 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 5547 Component Location - 25 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 5548 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation DESCRIPTION The fuel tank module is installed in the top of the fuel tank. The fuel tank module contains the following components: - An electric fuel transfer (lift) pump - Fuel reservoir - A separate in-tank fuel filter - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection - A special lockring to retain module to fuel tank - Fuel return line connection. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Removal Fuel Level Sensor: Service and Repair Removal REMOVAL 1. Drain and remove fuel tank. 2. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose. 3. Position Special Tool 9340 (3) into notches on outside edge of lockring (5). 4. Install 1/2 inch drive breaker bar (1) to tool 9340 (3). 5. Rotate breaker bar counterclockwise to remove lockring. 6. Remove lockring. The module will spring up slightly when lockring is removed. 7. Remove module from fuel tank. Be careful not to bend float arm while removing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Removal > Page 5554 Fuel Level Sensor: Service and Repair Installation INSTALLATION CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced. 1. Using a new seal (gasket), position fuel pump module into opening in fuel tank. 2. Position lockring (5) over top of fuel pump module. 3. Rotate module until embossed alignment arrow points to center alignment mark. This step must be performed to prevent float from contacting side of fuel tank. Also be sure fuel fitting on top of pump module is pointed to drivers side of vehicle. 4. Install Special Tool 9340 (3) to lockring. 5. Install 1/2 inch drive breaker (1) into Special Tool 9340 (3). 6. Tighten lockring (clockwise) until all seven notches have engaged. 7. Install fuel tank. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > High Idle Switch > Component Information > Locations High Idle Switch: Locations Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 5558 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 5559 High Idle Switch: Diagrams Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 5560 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5565 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5566 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5567 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5568 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5569 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5570 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5571 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5572 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5573 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5574 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5575 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5576 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5577 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5578 Information Bus: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5579 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5580 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5581 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5582 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5583 Information Bus: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-18-02 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5584 8w-18-03 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5585 8w-18-04 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5586 8w-18-05 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 5587 8w-18-06 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Description Knock Sensor: Description and Operation Description DESCRIPTION Two knock sensors are bolted into the cylinder block under the intake manifold 3.7L, 4.7L & 8.3L. Two knock sensors are also used with the 5.7L. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Description > Page 5592 Knock Sensor: Description and Operation Operation OPERATION Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5596 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5597 Main Relay (Computer/Fuel System): Diagrams Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5598 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5599 Main Relay (Computer/Fuel System): Testing and Inspection Fig.1 ASD And Fuel Pump Relay Terminals-Type 1 Fig.2 ASD And Fuel Pump Relay Terminals-Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5600 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Description Malfunction Indicator Lamp: Description and Operation Description DESCRIPTION A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. This indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. The MIL consists of a stencil-like cutout of the International Control and Display Symbol icon for Engine in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The MIL is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Description > Page 5605 Malfunction Indicator Lamp: Description and Operation Operation OPERATION The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or the Engine Control Module (ECM) on vehicles with a diesel engine has recorded a Diagnostic Trouble Code (DTC) for an On-Board Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the PCM or ECM over the Controller Area Network (CAN) data bus. The MIL Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the MIL for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the indicator is illuminated for about two seconds as a bulb test. The entire bulb test is a function of the PCM or ECM. - MIL Lamp-On Message - Each time the cluster receives an electronic MIL lamp-ON message from the PCM or ECM, the indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the PCM or ECM message. For some DTCs, if a problem does not recur, the PCM or ECM will send a lamp-OFF message automatically. Other DTCs may require that a fault be repaired and the PCM or ECM be reset before a lamp-OFF message will be sent. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the PCM or ECM for about 10 seconds, the MIL is illuminated by the instrument cluster to indicate a loss of bus communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the PCM or ECM. - Actuator Test - Each time the cluster is put through the actuator test, the MIL indicator will be turned ON during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM or ECM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. The PCM or ECM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the EMIC turns ON the MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and emissions systems may require service. For proper diagnosis of the fuel and emissions systems, the PCM, the ECM, the EMIC, the CAN data bus or the electronic communication related to MIL operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure Manifold Pressure/Vacuum Sensor: Locations Sensor-Manifold Absolute Pressure Component ID: 411 Component : SENSOR-MANIFOLD ABSOLUTE PRESSURE Connector: Name : SENSOR-MANIFOLD ABSOLUTE PRESSURE Color : GRAY # of pins : 3 Qualifier : (NGC) Pin Description Circuit 1 MAP SIGNAL K1 20VT/BR 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5610 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5611 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5612 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5613 Manifold Pressure/Vacuum Sensor: Locations Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5614 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5615 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5616 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5617 Component Location - 4 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5618 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5619 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 5620 Manifold Pressure/Vacuum Sensor: Locations Sensor-Temperature/Pressure-MAP Pick Up Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). Cab/Chassis Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Manifold Absolute Pressure Component ID: 411 Component : SENSOR-MANIFOLD ABSOLUTE PRESSURE Connector: Name : SENSOR-MANIFOLD ABSOLUTE PRESSURE Color : GRAY # of pins : 3 Qualifier : (NGC) Pin Description Circuit 1 MAP SIGNAL K1 20VT/BR 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5623 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5624 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5625 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5626 Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5627 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5628 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5629 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5630 Component Location - 4 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5631 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5632 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5633 Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Temperature/Pressure-MAP Component ID: 427 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A SENSOR GROUND K210 18DB/TN B INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG C 5 VOLT SUPPLY F855 18PK/YL D BOOST PRESSURE SENSOR SIGNAL K37 18LB Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5634 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 BOOST PRESSURE SENSOR SIGNAL K37 18BR 2 5 VOLT SUPPLY F855 18PK/YL 3 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 3 CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR K735 18BR/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 5635 4 SENSOR GROUND K916 18BR/OR Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Sensor-MAP Manifold Pressure/Vacuum Sensor: Description and Operation Sensor-MAP DESCRIPTION A combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is used. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Sensor-MAP > Page 5638 Manifold Pressure/Vacuum Sensor: Description and Operation Sensor-Temperature/Pressure-MAP OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Removal-Pick Up Models REMOVAL-PICK UP MODELS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 5641 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 5642 Manifold Pressure/Vacuum Sensor: Service and Repair Installation Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 5643 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5648 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5649 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5650 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5651 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5652 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5653 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5654 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5655 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5656 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5657 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5658 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5659 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5660 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5661 Oil Pressure Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5662 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5663 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5664 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5665 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5674 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5675 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5676 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5677 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5678 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5679 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5680 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5686 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5687 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5688 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 08-035-08 > Nov > 08 > Engine Controls - Oxygen Sensor Testing Information Oxygen Sensor: All Technical Service Bulletins Engine Controls - Oxygen Sensor Testing Information NUMBER: 08-035-08 GROUP: Electrical DATE: November 21, 2008 SUBJECT: Proper Testing Tools For Oxygen Sensor Terminals OVERVIEW: This bulletin describes the use of proper test probes to test the Oxygen (02) Sensor connector terminals equipped with the new TP2 style of sensor. MODELS: 2007-2009 (DH) 2500 Pick Up 2007-2009 (D1) 3500 Pick Up NOTE: This bulletin applies to models equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: The new TP2 style 02 sensors have smaller terminals that may be damaged (spread) when using standard Digital Volt Ohm Meter (DVOM) test probes. The recommended tool for these testing procedures is the Miller Tool # 6801 (Fig. 1) Two (2) of these probes are required when performing circuit tests as described in DealerCONNECT. The tool was originally included as part of Miller Tool # 6807 and # 8197A. Each of these kits contained one (1) # 6801 terminal probe. Two (2) additional Miller test probes # 6801 will be delivered to affected Dodge dealers shortly. Two (2) new terminal probes (# 6801) will be included and shipped as kit # 10190. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5698 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5699 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5700 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall O2 Sensor Replacement/ECM Software Update > Page 5705 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall O2 Sensor Replacement/ECM Software Update > Page 5706 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall O2 Sensor Replacement/ECM Software Update > Page 5707 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall O2 Sensor Replacement/ECM Software Update > Page 5708 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall O2 Sensor Replacement/ECM Software Update > Page 5709 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall O2 Sensor Replacement/ECM Software Update > Page 5710 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall O2 Sensor Replacement/ECM Software Update > Page 5711 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 08-035-08 > Nov > 08 > Engine Controls - Oxygen Sensor Testing Information Oxygen Sensor: All Technical Service Bulletins Engine Controls - Oxygen Sensor Testing Information NUMBER: 08-035-08 GROUP: Electrical DATE: November 21, 2008 SUBJECT: Proper Testing Tools For Oxygen Sensor Terminals OVERVIEW: This bulletin describes the use of proper test probes to test the Oxygen (02) Sensor connector terminals equipped with the new TP2 style of sensor. MODELS: 2007-2009 (DH) 2500 Pick Up 2007-2009 (D1) 3500 Pick Up NOTE: This bulletin applies to models equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: The new TP2 style 02 sensors have smaller terminals that may be damaged (spread) when using standard Digital Volt Ohm Meter (DVOM) test probes. The recommended tool for these testing procedures is the Miller Tool # 6801 (Fig. 1) Two (2) of these probes are required when performing circuit tests as described in DealerCONNECT. The tool was originally included as part of Miller Tool # 6807 and # 8197A. Each of these kits contained one (1) # 6801 terminal probe. Two (2) additional Miller test probes # 6801 will be delivered to affected Dodge dealers shortly. Two (2) new terminal probes (# 6801) will be included and shipped as kit # 10190. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5721 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5722 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5723 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5733 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5734 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5735 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5736 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5737 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5738 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5739 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen Oxygen Sensor: Locations Sensor - Oxygen The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5742 Oxygen Sensor: Locations Sensor - Oxygen 1/1 Component ID: 416 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : BLACK # of pins : 4 Qualifier : (3.7L/5.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5743 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5744 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5745 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5746 Connector: Name : SENSOR-OXYGEN 1/1 Color : GRAY # of pins : 4 Qualifier : (4.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5747 Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5748 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5749 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5750 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5751 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5752 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5753 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5754 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5755 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5756 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5757 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5758 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5759 Oxygen Sensor: Locations Sensor - Oxygen 1/2 Component ID: 417 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 4 Qualifier : (3.7L/5.7L LD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5760 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5761 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5762 Connector: Name : SENSOR-OXYGEN 1/2 Color : GRAY # of pins : 4 Qualifier : (4.7L/5.7L HD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5763 Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5764 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5765 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5766 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5767 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5768 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5769 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5770 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 5771 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor Oxygen Sensor: Diagrams Module-O2 Sensor Component ID: 207 Component : MODULE-O2 SENSOR Connector: Name : MODULE-O2 SENSOR Color : # of pins : 16 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 3 DIAGNOSTIC PORT LOW DATA LINK D132 20WT 4 O2 1/2 SIGNAL K141 20DB/YL 5 02 1/2 PUMP CURRENT K734 20BR/DG 6 O2 1/1 SIGNAL K41 20DB/LB 7 02 1/1 PUMP CURRENT K89 20BR/LG 8 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 9 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 10 GROUND Z902 20BK 11 DIAGNOSTIC PORT HIGH DATA LINK D133 20WT/OR 12 O2 1/2 RETURN K904 20DB/DG 13 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 14 O2 1/1 RETURN K902 20BR/DG 15 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 16 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB Connector: Name : MODULE-O2 SENSOR Color : # of pins : 16 Qualifier : (6.7L DIESEL) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5774 Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 3 DIAGNOSTIC PORT LOW DATA LINK D132 20WT 4 O2 1/2 SIGNAL K141 20DB/YL 5 02 1/2 PUMP CURRENT K734 20BR/DG 6 O2 1/1 SIGNAL K41 20DB/LB 7 02 1/1 PUMP CURRENT K89 20BR/LG 8 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 9 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 10 GROUND Z902 20BK 11 DIAGNOSTIC PORT HIGH DATA LINK D133 20WT/OR 12 O2 1/2 RETURN K904 20DB/DG 13 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 14 O2 1/1 RETURN K902 20BR/DG 15 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 16 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5775 Oxygen Sensor: Diagrams Sensor-Oxygen 1/1 Component ID: 416 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : BLACK # of pins : 4 Qualifier : (3.7L/5.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5776 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5777 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5778 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5779 Connector: Name : SENSOR-OXYGEN 1/1 Color : GRAY # of pins : 4 Qualifier : (4.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5780 Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5781 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5782 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5783 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5784 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5785 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5786 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5787 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5788 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5789 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5790 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5791 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5792 Oxygen Sensor: Diagrams Sensor-Oxygen 1/2 Component ID: 417 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 4 Qualifier : (3.7L/5.7L LD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5793 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5794 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5795 Connector: Name : SENSOR-OXYGEN 1/2 Color : GRAY # of pins : 4 Qualifier : (4.7L/5.7L HD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5796 Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5797 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5798 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5799 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5800 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5801 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5802 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5803 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5804 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models Oxygen Sensor: Description and Operation Description - Pick Up Models DESCRIPTION - PICK UP MODELS The two oxygen (O2) sensors (1) and (2) are located at each end of the #2 catalyst. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models > Page 5807 Oxygen Sensor: Description and Operation Operation - Pick Up Models OPERATION - PICK UP MODELS Two different six-wire O2 sensors are used. These sensors are titled 1/1 upstream (1), and 1/2 downstream (2). A separate O2 Sensor Module (1) is also used. The engine aftertreatment system monitors the O2 content in the diesel engine exhaust. The ECM monitors the exhaust gases for oxygen content and varies the rich/lean fuel mixture of the intake air fuel mixture to adjust the system. This diagnostic monitors the status message broadcast by the O2 Sensor Module (1) for the upstream O2 sensor's internal heater circuit. The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the O2 Sensor Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models > Page 5808 Oxygen Sensor: Description and Operation Oxygen Sensor Module Description - Pick Up Models DESCRIPTION - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). Operation - Pick Up Models OPERATION - PICK UP MODELS Two different six-wire O2 sensors are used. These sensors are titled 1/1 upstream, and 1/2 downstream. A separate O2 Sensor Module (1) is also used. The engine aftertreatment system monitors the O2 content in the diesel engine exhaust. The ECM monitors the exhaust gases for oxygen content and varies the rich/lean fuel mixture of the intake air fuel mixture to adjust the system. This diagnostic monitors the status message broadcast by the O2 Sensor Module (1) for the upstream O2 sensor's internal heater circuit. The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the O2 Sensor Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module Oxygen Sensor: Service and Repair Oxygen Sensor Module Removal - Pick Up Models REMOVAL - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). 1. Raise and support vehicle. 2. Disconnect electrical connector (2) at module (1). 3. Remove four bolts (3). 4. Remove module from frame rail. Installation - Pick Up Models INSTALLATION - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). 1. Position module (1) to frame rail (4). 2. Install four bolts (3). 3. Tighten bolts (3) to 6 Nm (53 in. lbs.) torque. 4. Connect electrical connector (2) to module (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 5811 5. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 5812 Oxygen Sensor: Service and Repair Removal REMOVAL - PICK UP MODELS The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: The exhaust manifold, exhaust pipes and catalytic converters become very hot during engine operation. Allow engine to cool before removing oxygen sensor. 1. Raise and support vehicle. 2. Disconnect main wire connector from O2S sensor pigtail harness. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove O2S sensor with an oxygen sensor removal and installation tool. 4. Clean threads in catalytic convertor using appropriate tap. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 5813 Oxygen Sensor: Service and Repair Installation INSTALLATION - PICK UP MODELS The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. Threads of NEW oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. Be careful not to get anti-seize compound on sensor tip. 1. Install O2S sensor. Tighten to 41 Nm (30 ft. lbs.) torque. 2. Connect O2S sensor pigtail harness to main wire harness connector. 3. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Diagrams Oxygen Sensor Relay: Diagrams 2007-2009 Ram truck, 6.7L, use an O2 module for oxygen sensor heater control. The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Description Power Steering Pressure Switch: Description and Operation Description DESCRIPTION A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will only be used on HD vehicles with the 5.7L engines. There is no pressure switch used for the 3.7L, 4.7L, 5.9LDiesel engine or the 5.7L LD vehicle pump. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Description > Page 5821 Power Steering Pressure Switch: Description and Operation Operation OPERATION The switch is used on the 5.7L V-8 engines HD vehicles only. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal Pressure Feedback Exhaust Sensor: Service and Repair Removal REMOVAL 1. Disconnect exhaust gas pressure sensor electrical connector (1). 2. Using a 6 point deepwell socket, remove exhaust gas sensor (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal > Page 5826 Pressure Feedback Exhaust Sensor: Service and Repair Installation INSTALLATION 1. Using a 6 point deepwell socket, install exhaust gas pressure sensor. 2. Tighten sensor to 18 Nm (13 ft. lbs.). 3. Connect exhaust gas pressure sensor electrical connector (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5832 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5833 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5834 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5835 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5836 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5837 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5838 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5839 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5840 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5841 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5842 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5843 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5844 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5845 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5846 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5847 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5848 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5849 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness Technical Service Bulletin # K01 Date: 100510 Recall - ECM Update For OBD Readiness May 2010 Dealer Service Instructions for: California Emissions Recall K01 Reprogram ECM OBD Readiness Effective immediately all repairs on involved vehicles are to be performed according to this notification. Service Bulletin 18-038-09 is no longer applicable for the involved vehicles only. Models 2003 (DR) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETC) and a California emission control system (sales code NAE). 2006-2007 (DH/D1) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETH) and a California emission control system (sales code NAE). 2007 (DC) Dodge Ram Truck (3500 series cab chassis) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ) and a California emission control system (sales code NAE) built through January 5, 2007 (MDH010508). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process or GRS DealerCONNECT functions. Subject The Engine Control Module (ECM) on about 25,208 of the above vehicles may fail to accurately report diagnostic system information with some generic scan tools. This may cause the vehicle to be rejected or fail an Inspection/Maintenance Test (also known as a Smog Check). Repair The Engine Control Module (ECM) must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Part Number Description 04275086AB Authorized Modifications Label Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5858 The special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the label plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5859 To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: The DRBIII(R) must be used to perform this recall on 2003 Model Year (MY) vehicles. The 2003 MY procedure is found in Section D of the Service Procedure. Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall on 2006-2007 MY vehicles. This procedure must be performed with software release level 10.03 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5860 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's" button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section E. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5861 h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section E. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5862 e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 10. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 9. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 10. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 11. Continue with Section E. Install Authorized Modification Label. D. Reprogram the ECM Using DRBIII(R): The DealerCONNECT System, DRBIII(R) (Diagnostic Readout Box scan tool), CH7000A flash cable and CH7035B data cable are required to perform this repair. Do not attempt to perform the flash procedure using an outdated CH7000/CH7001 flash cable. NOTE: Whenever a controller is reprogrammed, the software in the DRBIII scan tool must be programmed with the latest revision level available. NOTE: If the flash process is interrupted or aborted, the flash should be restarted and then follow the directions on the DRBIII scan tool. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5863 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the DRBIII CH7000A flash cable from the DRBIII scan tool to the data link connector located inside the vehicle under the steering column. 3. Connect the CH7035B data cable from the DealerCONNECT machine to the MDS port on the DRBIII scan tool. 4. Place the vehicle's ignition key in the "RUN" position. 5. From the DealerCONNECT "WELCOME" screen, enter your "User I.D.," "Password" and "Dealer Code". 6. From the DealerCONNECT "HOME PAGE" select the "SERVICE" tab. 7. From the "SERVICE" tab screen select "TechTOOLS". 8. If the DRBIII scan tool does not "Auto Connect" select # 2 on the DRBIII key pad "Connect to TechCONNECT". 9. After the "Auto Connect" process is complete, select "READ PART NUMBER(S) FROM VEHICLE" on the TechCONNECT screen. 10. Continue following the TechCONNECT on-screen instructions. 11. Select the applicable update calibration. 12. Select the "DRBIII" button located at the bottom of the TechCONNECT monitor screen. 13. Select the "DOWNLOAD / UPDATE" button located next to the "DRBIII" button. NOTE: The system software will automatically download to the DRBIII scan tool. 14. After the software download to the DRBIII scan tool is complete, close the "DOWNLOAD / UPDATE PROGRESS" window. 15. Disconnect the DRBIII scan tool from the TechCONNECT CH7035B data cable. 16. Select # 1 "RETURN TO NORMAL MODE" on the DRBIII scan tool. 17. Use the following procedure to download the flash from the DRBIII scan tool to the vehicle. a. Select # 7 "VEHICLE FLASH" on the DRBIII scan tool. b. Follow the directions displayed on the DRBIII scan tool screen. c. After the reprogramming is complete, record the new module part number displayed on the DRBIII scan tool screen. d. Press the "PAGE BACK" button on the DRBIII scan tool. 18. Due to the ECM flash procedure, Diagnostic Trouble Codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS, ORC) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules, record the trouble codes, and erase the trouble codes using the following procedure: a. Turn the vehicle's ignition key to the "RUN" position. b. From the DRBIII scan tool Main Menu select # 1 "DRBIII Stand-Alone". c. From the DRBIII scan tool Stand-Alone menu select # 3 "Vehicle Module Scan". d. From the DRBIII scan tool Vehicle Module Scan menu select # 1 "1998 - 2005 Module Scan". e. Select "YES" on the DRBIII scan tool key pad to scan for DTC's. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5864 f. Follow the instructions on the DRBIII scan tool screen. g. Once the scanning process is complete, the DRBIII scan tool will display a list of all the modules. Modules on the list that have an asterisk next to them have DTC's that need to be cleared. h. Select the module that needs to have the DTC's cleared and follow the instructions on the DRBIII scan tool screen to clear the DTC's. i. Turn the vehicle's ignition key to the "OFF" position. NOTE: Erase any DTC's in the ECM only after all other modules have had their DTC's erased. 19. Disconnect the DRBIII scan tool from the vehicle. 20. Turn off the battery charger and disconnect it from the vehicle. 21. Continue with Section E. Install Authorized Modification Label. E. Install the Authorized Modifications Label: 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5865 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5870 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5871 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5872 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5873 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5874 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5875 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5876 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-003-10 > Sep > 10 > Engine Controls - ECM Update for Fan Clutch Operation Engine Control Module: Customer Interest Engine Controls - ECM Update for Fan Clutch Operation NUMBER: 07-003-10 GROUP: Cooling DATE: September 09, 2010 SUBJECT: High Coolant Temperatures On Vehicles Equipped With Snow Plows OVERVIEW: This bulletin provides information on how to program the Engine Control Module (ECM) to force the fan clutch to fully engage at all operating conditions MODELS: 2007 - 2010 DC/DM Ram 3500/4500/5500 Cab Chassis Trucks 2011 DD/DP Ram 3500/4500/5500 Cab Chassis Trucks NOTE: This bulletin applies to vehicles equipped with the 6.7L Cummins Diesel engine (Sales Code ETJ) DISCUSSION: Customers that operate their vehicle with a snowplow attached to the vehicle may cause the airflow passing through the radiator to be disrupted resulting in higher than normal engine temperatures The 6~7L Cummins ECM is equipped with software that can fully engage the fan clutch to allow an increase of airflow through the radiator Customers can initiate the fan clutch operation by performing the following button sequence NOTE: 2007 early 2009 models were not originally equipped with the fan clutch software however, recently released software does include this enhancement Ensure that the ECM software is at the latest level and if not, flash the ECM Refer to Service Bulletin 18-020-10 for additional information 1. Turn the ignition key to the run position or start the truck 2. Simultaneously press and release the Cruise Control "Cancel" button/lever and the "Exhaust Brake" button. Repeat this sequence four times within five seconds. The chime will sound twice as an audible indicator that the function is engaged 3. To disable the function, repeat the same procedure The chime will sound four times as an audible indicator that the function is disengaged NOTE: Customer's should be made aware that an increase in fan noise and a decrease in fuel economy may result when using this feature. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements Engine Control Module: Customer Interest Engine Controls - Engine Systems/Exhaust Enhancements NUMBER: 18-020-10 GROUP: Vehicle Performance DATE: June 10, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-06, DATED DECEMBER 05, 2006 AND 18-001-09, DATED JANUARY 21, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. Either wiTECH OR StarMOBILE DESKTOP CLIENT can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. StarMOBILE® SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. SUBJECT: FLASH: Engine Systems And Exhaust Aftertreatment Systems Enhancements OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement based on customer use and mileage accumulation. This bulletin involves: ^ Selectively erasing and reprogramming the Engine Control Module (PCM), 2007 - 2010 MY. ^ Selectively erasing and reprogramming the Cab Compartment Node (CCN), 2007 & 2008 MY. ^ If CCN is updated; provide a Customer Information Sheet explaining the overhead display messages. ^ One of several software changes allows for "Net Zero" and "Net Reduction" which will cause noticeable changes in idle speeds. Customers should be informed of these changes. They are explained in DISCUSSION, Improvements that address erroneous MIL illumination for DTC P0106, P0191, P2262 and P2299 DTC's, (spelled out in DISCUSSION below). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. MODELS: 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) 2008 - 2010 (DM) Ram Truck (4500/5500 Cab Chassis) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). NOTE: For some 2007 MY vehicles, the ECM flash is addressed in Recall K01, Dated May, 2010. Where applicable. please use the Recall to update the ECM and this bulletin to update the CCN software. DISCUSSION: Cab chassis trucks equipped with a 6.7L Cummins diesel have a number of software improvements available. This latest Service Bulletin (SB) will include improvements to prevent erroneous Malfunction Indicator Lamp (MIL) illumination: ^ P000F - Fuel System Over Pressure Relief Valve Activated Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 5886 ^ P0087 - Fuel Rail Pressure Too Low ^ P0106 - Manifold Absolute Pressure Sensor Performance ^ P0191 - Fuel Rail Pressure Sensor Circuit Performance ^ P1011 - Fuel Pump Delivery Pressure Too Low ^ P2299 - Brake Pedal Position / Accelerator Pedal Position Incompatible ^ P2262 - Turbocharger Boost Pressure Not Detected - Mechanical Other updates will include the following operational and diagnostic improvements: 1. Stationary DeSoot is now available with this software. This feature works similar to pick up truck (DH/D1) models. 2. New DTC added for P2563 - Turbocharger Boost Control Position Sensor Performance. This DTC indicates diminished variable geometry turbocharger travel, which is resolved by replacing the turbocharger. Diagnosis and repair procedures for the DTC have been published in DTC-Based Diagnostics in TechConnect. 3. The latest PCM software includes a new extended idle feature to accommodate the extended idle times present in some duty cycles. This feature may help to reduce the accumulation of soot in the exhaust aftertreatment system when the engine is idling for an extended period of time. Briefly how this feature works: a. As needed, the engine enters an idling mode which dramatically reduces the rate of soot accumulation in the diesel particulate filter (called "Net Zero"). Further, under extended idle periods of 5 minutes or longer, the engine enters a mode which reduces the amount of soot accumulated in the diesel particulate filter (called "Net Reduction"). While in these modes, the idle speed increases to 900 RPM for a period of time. The idle speed may return to normal idle speed and then return to 900 RPM to repeat this cycle during very long idle periods. b. These modes occur automatically depending on the need to regenerate the DPF as long as the vehicle is not driven over 20 MPH or operated at high load. If the vehicle is driven over 20 MPH normal mobile desoot will occur automatically. 4. New scan tool driven fuel system diagnostic tests (same as previously released in the pick up) now available for cab chassis. DIAGNOSIS: 1. Using the scan tool, determine current software level of the PCM and CCN. Record on the repair order, for later use, the current PCM and CCN software level part numbers. Proceed to the next step. 2. Compare the current PCM software level part number with software available in the scantool. Determine if the current PCM software level part number, recorded in Step # 1, is programmable to a higher level. 3. Is the part number of the current PCM level software (recorded in Step # 1) at the latest level listed in the scan tool? a. If YES >> then the PCM DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. b. If NO >> then the PCM DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. 4. Is the vehicle a 2007 OR 2008 MY? a. Yes >>> Proceed to Step # 5. b. No >>> 2009 MY proceed to the REPAIR PROCEDURE as required. 5. Determine if the current CCN module level software part number, that was recorded earlier in Step # 1, is one of the following (or with a higher suffix): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 5887 a. 05172187AH (or higher) = 2007 DC (3500). b. 05172334AG (or higher) = 2008 DC (3500) / DM (3500/4500). c. 2009 & 2010 MY vehicles came equipped with proper CCN software. 6. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 5? a. If YES >>> then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. b. If NO >>> then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. PARTS REQUIRED: REPAIR PROCEDURE; ECM MODULE REPROGRAM: NOTE: The wiTECH diagnostic application is the preferred method for flashing ECU's. Help using the wiTECH diagnostic application for flashing an ECU is available by selecting "Help" then "Help Contents" at the top of the wiTECH diagnostic application window. NOTE: The wiTECH software level must be at release 10.04 or higher to perform this procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. If required, as determined in DIAGNOSIS, above: reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > 8E - Electronic Control Modules >MODULE, Engine Control, Diesel > Service Information > Standard Procedure > PCM/ECM Programming - DIESEL. After PCM reprogramming, the following must be performed: a. Clear any DIG's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 3. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. 4. If required, as determined in DIAGNOSIS, above: reprogram the CCN using one of the following procedures, (based on scan tool use). 5. Was it determined in DIAGNOSIS, Step # 6 above, the CCN required updating? a. Yes >>> Proceed to appropriate CCN Module Reprogram Procedure Below, based on the scantool used. b. No >>> Repair is complete. NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 5888 NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. CCN MODULE REPROGRAM - USING wiTECH(R): 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id and "Password", then select "OK". 6. Select the "Next tab at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash" screen follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF position", remove the wiPOD(R) and battery charger from the vehicle. StarMOBILE(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident" flash file for statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 5889 b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step Se, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number (displayed at the end of the "Resident flash file for statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 5890 Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "Exhaust Filter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required - See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test Engine Control Module: Customer Interest Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 5895 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set Engine Control Module: Customer Interest Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 5900 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 5901 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: Customer Interest Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5906 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5907 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5908 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5909 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 07-003-10 > Sep > 10 > Engine Controls - ECM Update for Fan Clutch Operation Engine Control Module: All Technical Service Bulletins Engine Controls - ECM Update for Fan Clutch Operation NUMBER: 07-003-10 GROUP: Cooling DATE: September 09, 2010 SUBJECT: High Coolant Temperatures On Vehicles Equipped With Snow Plows OVERVIEW: This bulletin provides information on how to program the Engine Control Module (ECM) to force the fan clutch to fully engage at all operating conditions MODELS: 2007 - 2010 DC/DM Ram 3500/4500/5500 Cab Chassis Trucks 2011 DD/DP Ram 3500/4500/5500 Cab Chassis Trucks NOTE: This bulletin applies to vehicles equipped with the 6.7L Cummins Diesel engine (Sales Code ETJ) DISCUSSION: Customers that operate their vehicle with a snowplow attached to the vehicle may cause the airflow passing through the radiator to be disrupted resulting in higher than normal engine temperatures The 6~7L Cummins ECM is equipped with software that can fully engage the fan clutch to allow an increase of airflow through the radiator Customers can initiate the fan clutch operation by performing the following button sequence NOTE: 2007 early 2009 models were not originally equipped with the fan clutch software however, recently released software does include this enhancement Ensure that the ECM software is at the latest level and if not, flash the ECM Refer to Service Bulletin 18-020-10 for additional information 1. Turn the ignition key to the run position or start the truck 2. Simultaneously press and release the Cruise Control "Cancel" button/lever and the "Exhaust Brake" button. Repeat this sequence four times within five seconds. The chime will sound twice as an audible indicator that the function is engaged 3. To disable the function, repeat the same procedure The chime will sound four times as an audible indicator that the function is disengaged NOTE: Customer's should be made aware that an increase in fan noise and a decrease in fuel economy may result when using this feature. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Systems/Exhaust Enhancements NUMBER: 18-020-10 GROUP: Vehicle Performance DATE: June 10, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-06, DATED DECEMBER 05, 2006 AND 18-001-09, DATED JANUARY 21, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. Either wiTECH OR StarMOBILE DESKTOP CLIENT can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. StarMOBILE® SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. SUBJECT: FLASH: Engine Systems And Exhaust Aftertreatment Systems Enhancements OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement based on customer use and mileage accumulation. This bulletin involves: ^ Selectively erasing and reprogramming the Engine Control Module (PCM), 2007 - 2010 MY. ^ Selectively erasing and reprogramming the Cab Compartment Node (CCN), 2007 & 2008 MY. ^ If CCN is updated; provide a Customer Information Sheet explaining the overhead display messages. ^ One of several software changes allows for "Net Zero" and "Net Reduction" which will cause noticeable changes in idle speeds. Customers should be informed of these changes. They are explained in DISCUSSION, Improvements that address erroneous MIL illumination for DTC P0106, P0191, P2262 and P2299 DTC's, (spelled out in DISCUSSION below). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. MODELS: 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) 2008 - 2010 (DM) Ram Truck (4500/5500 Cab Chassis) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). NOTE: For some 2007 MY vehicles, the ECM flash is addressed in Recall K01, Dated May, 2010. Where applicable. please use the Recall to update the ECM and this bulletin to update the CCN software. DISCUSSION: Cab chassis trucks equipped with a 6.7L Cummins diesel have a number of software improvements available. This latest Service Bulletin (SB) will include improvements to prevent erroneous Malfunction Indicator Lamp (MIL) illumination: ^ P000F - Fuel System Over Pressure Relief Valve Activated Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 5919 ^ P0087 - Fuel Rail Pressure Too Low ^ P0106 - Manifold Absolute Pressure Sensor Performance ^ P0191 - Fuel Rail Pressure Sensor Circuit Performance ^ P1011 - Fuel Pump Delivery Pressure Too Low ^ P2299 - Brake Pedal Position / Accelerator Pedal Position Incompatible ^ P2262 - Turbocharger Boost Pressure Not Detected - Mechanical Other updates will include the following operational and diagnostic improvements: 1. Stationary DeSoot is now available with this software. This feature works similar to pick up truck (DH/D1) models. 2. New DTC added for P2563 - Turbocharger Boost Control Position Sensor Performance. This DTC indicates diminished variable geometry turbocharger travel, which is resolved by replacing the turbocharger. Diagnosis and repair procedures for the DTC have been published in DTC-Based Diagnostics in TechConnect. 3. The latest PCM software includes a new extended idle feature to accommodate the extended idle times present in some duty cycles. This feature may help to reduce the accumulation of soot in the exhaust aftertreatment system when the engine is idling for an extended period of time. Briefly how this feature works: a. As needed, the engine enters an idling mode which dramatically reduces the rate of soot accumulation in the diesel particulate filter (called "Net Zero"). Further, under extended idle periods of 5 minutes or longer, the engine enters a mode which reduces the amount of soot accumulated in the diesel particulate filter (called "Net Reduction"). While in these modes, the idle speed increases to 900 RPM for a period of time. The idle speed may return to normal idle speed and then return to 900 RPM to repeat this cycle during very long idle periods. b. These modes occur automatically depending on the need to regenerate the DPF as long as the vehicle is not driven over 20 MPH or operated at high load. If the vehicle is driven over 20 MPH normal mobile desoot will occur automatically. 4. New scan tool driven fuel system diagnostic tests (same as previously released in the pick up) now available for cab chassis. DIAGNOSIS: 1. Using the scan tool, determine current software level of the PCM and CCN. Record on the repair order, for later use, the current PCM and CCN software level part numbers. Proceed to the next step. 2. Compare the current PCM software level part number with software available in the scantool. Determine if the current PCM software level part number, recorded in Step # 1, is programmable to a higher level. 3. Is the part number of the current PCM level software (recorded in Step # 1) at the latest level listed in the scan tool? a. If YES >> then the PCM DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. b. If NO >> then the PCM DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. 4. Is the vehicle a 2007 OR 2008 MY? a. Yes >>> Proceed to Step # 5. b. No >>> 2009 MY proceed to the REPAIR PROCEDURE as required. 5. Determine if the current CCN module level software part number, that was recorded earlier in Step # 1, is one of the following (or with a higher suffix): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 5920 a. 05172187AH (or higher) = 2007 DC (3500). b. 05172334AG (or higher) = 2008 DC (3500) / DM (3500/4500). c. 2009 & 2010 MY vehicles came equipped with proper CCN software. 6. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 5? a. If YES >>> then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. b. If NO >>> then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. PARTS REQUIRED: REPAIR PROCEDURE; ECM MODULE REPROGRAM: NOTE: The wiTECH diagnostic application is the preferred method for flashing ECU's. Help using the wiTECH diagnostic application for flashing an ECU is available by selecting "Help" then "Help Contents" at the top of the wiTECH diagnostic application window. NOTE: The wiTECH software level must be at release 10.04 or higher to perform this procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. If required, as determined in DIAGNOSIS, above: reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > 8E - Electronic Control Modules >MODULE, Engine Control, Diesel > Service Information > Standard Procedure > PCM/ECM Programming - DIESEL. After PCM reprogramming, the following must be performed: a. Clear any DIG's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 3. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. 4. If required, as determined in DIAGNOSIS, above: reprogram the CCN using one of the following procedures, (based on scan tool use). 5. Was it determined in DIAGNOSIS, Step # 6 above, the CCN required updating? a. Yes >>> Proceed to appropriate CCN Module Reprogram Procedure Below, based on the scantool used. b. No >>> Repair is complete. NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 5921 NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. CCN MODULE REPROGRAM - USING wiTECH(R): 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id and "Password", then select "OK". 6. Select the "Next tab at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash" screen follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF position", remove the wiPOD(R) and battery charger from the vehicle. StarMOBILE(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident" flash file for statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 5922 b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step Se, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number (displayed at the end of the "Resident flash file for statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 5923 Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "Exhaust Filter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required - See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test Engine Control Module: All Technical Service Bulletins Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 5928 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 5933 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 5934 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness Technical Service Bulletin # K01 Date: 100510 Recall - ECM Update For OBD Readiness May 2010 Dealer Service Instructions for: California Emissions Recall K01 Reprogram ECM OBD Readiness Effective immediately all repairs on involved vehicles are to be performed according to this notification. Service Bulletin 18-038-09 is no longer applicable for the involved vehicles only. Models 2003 (DR) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETC) and a California emission control system (sales code NAE). 2006-2007 (DH/D1) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETH) and a California emission control system (sales code NAE). 2007 (DC) Dodge Ram Truck (3500 series cab chassis) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ) and a California emission control system (sales code NAE) built through January 5, 2007 (MDH010508). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process or GRS DealerCONNECT functions. Subject The Engine Control Module (ECM) on about 25,208 of the above vehicles may fail to accurately report diagnostic system information with some generic scan tools. This may cause the vehicle to be rejected or fail an Inspection/Maintenance Test (also known as a Smog Check). Repair The Engine Control Module (ECM) must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Part Number Description 04275086AB Authorized Modifications Label Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5939 The special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the label plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5940 To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: The DRBIII(R) must be used to perform this recall on 2003 Model Year (MY) vehicles. The 2003 MY procedure is found in Section D of the Service Procedure. Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall on 2006-2007 MY vehicles. This procedure must be performed with software release level 10.03 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5941 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's" button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section E. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5942 h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section E. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5943 e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 10. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 9. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 10. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 11. Continue with Section E. Install Authorized Modification Label. D. Reprogram the ECM Using DRBIII(R): The DealerCONNECT System, DRBIII(R) (Diagnostic Readout Box scan tool), CH7000A flash cable and CH7035B data cable are required to perform this repair. Do not attempt to perform the flash procedure using an outdated CH7000/CH7001 flash cable. NOTE: Whenever a controller is reprogrammed, the software in the DRBIII scan tool must be programmed with the latest revision level available. NOTE: If the flash process is interrupted or aborted, the flash should be restarted and then follow the directions on the DRBIII scan tool. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5944 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the DRBIII CH7000A flash cable from the DRBIII scan tool to the data link connector located inside the vehicle under the steering column. 3. Connect the CH7035B data cable from the DealerCONNECT machine to the MDS port on the DRBIII scan tool. 4. Place the vehicle's ignition key in the "RUN" position. 5. From the DealerCONNECT "WELCOME" screen, enter your "User I.D.," "Password" and "Dealer Code". 6. From the DealerCONNECT "HOME PAGE" select the "SERVICE" tab. 7. From the "SERVICE" tab screen select "TechTOOLS". 8. If the DRBIII scan tool does not "Auto Connect" select # 2 on the DRBIII key pad "Connect to TechCONNECT". 9. After the "Auto Connect" process is complete, select "READ PART NUMBER(S) FROM VEHICLE" on the TechCONNECT screen. 10. Continue following the TechCONNECT on-screen instructions. 11. Select the applicable update calibration. 12. Select the "DRBIII" button located at the bottom of the TechCONNECT monitor screen. 13. Select the "DOWNLOAD / UPDATE" button located next to the "DRBIII" button. NOTE: The system software will automatically download to the DRBIII scan tool. 14. After the software download to the DRBIII scan tool is complete, close the "DOWNLOAD / UPDATE PROGRESS" window. 15. Disconnect the DRBIII scan tool from the TechCONNECT CH7035B data cable. 16. Select # 1 "RETURN TO NORMAL MODE" on the DRBIII scan tool. 17. Use the following procedure to download the flash from the DRBIII scan tool to the vehicle. a. Select # 7 "VEHICLE FLASH" on the DRBIII scan tool. b. Follow the directions displayed on the DRBIII scan tool screen. c. After the reprogramming is complete, record the new module part number displayed on the DRBIII scan tool screen. d. Press the "PAGE BACK" button on the DRBIII scan tool. 18. Due to the ECM flash procedure, Diagnostic Trouble Codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS, ORC) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules, record the trouble codes, and erase the trouble codes using the following procedure: a. Turn the vehicle's ignition key to the "RUN" position. b. From the DRBIII scan tool Main Menu select # 1 "DRBIII Stand-Alone". c. From the DRBIII scan tool Stand-Alone menu select # 3 "Vehicle Module Scan". d. From the DRBIII scan tool Vehicle Module Scan menu select # 1 "1998 - 2005 Module Scan". e. Select "YES" on the DRBIII scan tool key pad to scan for DTC's. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5945 f. Follow the instructions on the DRBIII scan tool screen. g. Once the scanning process is complete, the DRBIII scan tool will display a list of all the modules. Modules on the list that have an asterisk next to them have DTC's that need to be cleared. h. Select the module that needs to have the DTC's cleared and follow the instructions on the DRBIII scan tool screen to clear the DTC's. i. Turn the vehicle's ignition key to the "OFF" position. NOTE: Erase any DTC's in the ECM only after all other modules have had their DTC's erased. 19. Disconnect the DRBIII scan tool from the vehicle. 20. Turn off the battery charger and disconnect it from the vehicle. 21. Continue with Section E. Install Authorized Modification Label. E. Install the Authorized Modifications Label: 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 5946 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5951 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5952 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5953 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5954 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5959 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5960 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5961 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5962 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5963 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5964 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5965 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-030-07 > Apr > 07 > Engine Controls - Engine Off Idle Speed Limit Feature Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Off Idle Speed Limit Feature NUMBER: 18-030-07 GROUP: Vehicle Performance DATE: April 26, 2007 SUBJECT: Engine Off-Idle Speed Limit Feature To Protect Turbocharger When Vehicle Is Not Moving OVERVIEW: This bulletin involves a discussion regarding an engine control feature that limits engine off-idle speeds when the vehicle is not moving. MODELS: 2004 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 5.9L or a 6.7L Cummins turbo-diesel engine (sale codes: ETC, ETH, or ETJ). DISCUSSION: Dependent upon engine coolant temperature, the Engine Control Module (ECM) will temporarily delay (limit) the maximum engine speed when the vehicle is not moving. For automatic transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph, and when the transmission selector is in either the neutral or park position. For manual transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph. This ECM feature is used to protect the engine turbocharger. By temporarily limiting the vehicle engine speed, the shaft speed of the engine turbocharger is controlled to a low speed. This delay in maximum engine and turbo-charger shaft speed allows for sufficient oil lubrication to the turbocharger shaft bearings. Satisfactory oil lubrication of the turbocharger shaft bearings is important for long term turbocharger durability. The maximum engine speed for the 5.9L engine is temporarily limited to 1,600 RPM's when the above conditions are met. The 6.7L engine speed is temporarily limited to 1,200 RPM's when the above conditions are met. The length of time that the maximum engine speed is temporarily limited is dependent upon engine coolant temperature. Refer to the table to determine the amount of Time Delay. NOTE: The time delay values supplied in the table are an approximation and may vary per application. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Engine Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 5974 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 5975 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 5976 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 07-003-10 > Sep > 10 > Engine Controls - ECM Update for Fan Clutch Operation Engine Control Module: All Technical Service Bulletins Engine Controls - ECM Update for Fan Clutch Operation NUMBER: 07-003-10 GROUP: Cooling DATE: September 09, 2010 SUBJECT: High Coolant Temperatures On Vehicles Equipped With Snow Plows OVERVIEW: This bulletin provides information on how to program the Engine Control Module (ECM) to force the fan clutch to fully engage at all operating conditions MODELS: 2007 - 2010 DC/DM Ram 3500/4500/5500 Cab Chassis Trucks 2011 DD/DP Ram 3500/4500/5500 Cab Chassis Trucks NOTE: This bulletin applies to vehicles equipped with the 6.7L Cummins Diesel engine (Sales Code ETJ) DISCUSSION: Customers that operate their vehicle with a snowplow attached to the vehicle may cause the airflow passing through the radiator to be disrupted resulting in higher than normal engine temperatures The 6~7L Cummins ECM is equipped with software that can fully engage the fan clutch to allow an increase of airflow through the radiator Customers can initiate the fan clutch operation by performing the following button sequence NOTE: 2007 early 2009 models were not originally equipped with the fan clutch software however, recently released software does include this enhancement Ensure that the ECM software is at the latest level and if not, flash the ECM Refer to Service Bulletin 18-020-10 for additional information 1. Turn the ignition key to the run position or start the truck 2. Simultaneously press and release the Cruise Control "Cancel" button/lever and the "Exhaust Brake" button. Repeat this sequence four times within five seconds. The chime will sound twice as an audible indicator that the function is engaged 3. To disable the function, repeat the same procedure The chime will sound four times as an audible indicator that the function is disengaged NOTE: Customer's should be made aware that an increase in fan noise and a decrease in fuel economy may result when using this feature. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Systems/Exhaust Enhancements NUMBER: 18-020-10 GROUP: Vehicle Performance DATE: June 10, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-06, DATED DECEMBER 05, 2006 AND 18-001-09, DATED JANUARY 21, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. Either wiTECH OR StarMOBILE DESKTOP CLIENT can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. StarMOBILE® SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. SUBJECT: FLASH: Engine Systems And Exhaust Aftertreatment Systems Enhancements OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement based on customer use and mileage accumulation. This bulletin involves: ^ Selectively erasing and reprogramming the Engine Control Module (PCM), 2007 - 2010 MY. ^ Selectively erasing and reprogramming the Cab Compartment Node (CCN), 2007 & 2008 MY. ^ If CCN is updated; provide a Customer Information Sheet explaining the overhead display messages. ^ One of several software changes allows for "Net Zero" and "Net Reduction" which will cause noticeable changes in idle speeds. Customers should be informed of these changes. They are explained in DISCUSSION, Improvements that address erroneous MIL illumination for DTC P0106, P0191, P2262 and P2299 DTC's, (spelled out in DISCUSSION below). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. MODELS: 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) 2008 - 2010 (DM) Ram Truck (4500/5500 Cab Chassis) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). NOTE: For some 2007 MY vehicles, the ECM flash is addressed in Recall K01, Dated May, 2010. Where applicable. please use the Recall to update the ECM and this bulletin to update the CCN software. DISCUSSION: Cab chassis trucks equipped with a 6.7L Cummins diesel have a number of software improvements available. This latest Service Bulletin (SB) will include improvements to prevent erroneous Malfunction Indicator Lamp (MIL) illumination: ^ P000F - Fuel System Over Pressure Relief Valve Activated Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 5986 ^ P0087 - Fuel Rail Pressure Too Low ^ P0106 - Manifold Absolute Pressure Sensor Performance ^ P0191 - Fuel Rail Pressure Sensor Circuit Performance ^ P1011 - Fuel Pump Delivery Pressure Too Low ^ P2299 - Brake Pedal Position / Accelerator Pedal Position Incompatible ^ P2262 - Turbocharger Boost Pressure Not Detected - Mechanical Other updates will include the following operational and diagnostic improvements: 1. Stationary DeSoot is now available with this software. This feature works similar to pick up truck (DH/D1) models. 2. New DTC added for P2563 - Turbocharger Boost Control Position Sensor Performance. This DTC indicates diminished variable geometry turbocharger travel, which is resolved by replacing the turbocharger. Diagnosis and repair procedures for the DTC have been published in DTC-Based Diagnostics in TechConnect. 3. The latest PCM software includes a new extended idle feature to accommodate the extended idle times present in some duty cycles. This feature may help to reduce the accumulation of soot in the exhaust aftertreatment system when the engine is idling for an extended period of time. Briefly how this feature works: a. As needed, the engine enters an idling mode which dramatically reduces the rate of soot accumulation in the diesel particulate filter (called "Net Zero"). Further, under extended idle periods of 5 minutes or longer, the engine enters a mode which reduces the amount of soot accumulated in the diesel particulate filter (called "Net Reduction"). While in these modes, the idle speed increases to 900 RPM for a period of time. The idle speed may return to normal idle speed and then return to 900 RPM to repeat this cycle during very long idle periods. b. These modes occur automatically depending on the need to regenerate the DPF as long as the vehicle is not driven over 20 MPH or operated at high load. If the vehicle is driven over 20 MPH normal mobile desoot will occur automatically. 4. New scan tool driven fuel system diagnostic tests (same as previously released in the pick up) now available for cab chassis. DIAGNOSIS: 1. Using the scan tool, determine current software level of the PCM and CCN. Record on the repair order, for later use, the current PCM and CCN software level part numbers. Proceed to the next step. 2. Compare the current PCM software level part number with software available in the scantool. Determine if the current PCM software level part number, recorded in Step # 1, is programmable to a higher level. 3. Is the part number of the current PCM level software (recorded in Step # 1) at the latest level listed in the scan tool? a. If YES >> then the PCM DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. b. If NO >> then the PCM DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. 4. Is the vehicle a 2007 OR 2008 MY? a. Yes >>> Proceed to Step # 5. b. No >>> 2009 MY proceed to the REPAIR PROCEDURE as required. 5. Determine if the current CCN module level software part number, that was recorded earlier in Step # 1, is one of the following (or with a higher suffix): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 5987 a. 05172187AH (or higher) = 2007 DC (3500). b. 05172334AG (or higher) = 2008 DC (3500) / DM (3500/4500). c. 2009 & 2010 MY vehicles came equipped with proper CCN software. 6. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 5? a. If YES >>> then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. b. If NO >>> then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. PARTS REQUIRED: REPAIR PROCEDURE; ECM MODULE REPROGRAM: NOTE: The wiTECH diagnostic application is the preferred method for flashing ECU's. Help using the wiTECH diagnostic application for flashing an ECU is available by selecting "Help" then "Help Contents" at the top of the wiTECH diagnostic application window. NOTE: The wiTECH software level must be at release 10.04 or higher to perform this procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. If required, as determined in DIAGNOSIS, above: reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > 8E - Electronic Control Modules >MODULE, Engine Control, Diesel > Service Information > Standard Procedure > PCM/ECM Programming - DIESEL. After PCM reprogramming, the following must be performed: a. Clear any DIG's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 3. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. 4. If required, as determined in DIAGNOSIS, above: reprogram the CCN using one of the following procedures, (based on scan tool use). 5. Was it determined in DIAGNOSIS, Step # 6 above, the CCN required updating? a. Yes >>> Proceed to appropriate CCN Module Reprogram Procedure Below, based on the scantool used. b. No >>> Repair is complete. NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 5988 NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. CCN MODULE REPROGRAM - USING wiTECH(R): 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id and "Password", then select "OK". 6. Select the "Next tab at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash" screen follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF position", remove the wiPOD(R) and battery charger from the vehicle. StarMOBILE(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident" flash file for statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 5989 b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step Se, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number (displayed at the end of the "Resident flash file for statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 5990 Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "Exhaust Filter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required - See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test Engine Control Module: All Technical Service Bulletins Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 5995 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 6000 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 6001 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 6006 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 6007 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 6008 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 6009 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-030-07 > Apr > 07 > Engine Controls - Engine Off Idle Speed Limit Feature Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Off Idle Speed Limit Feature NUMBER: 18-030-07 GROUP: Vehicle Performance DATE: April 26, 2007 SUBJECT: Engine Off-Idle Speed Limit Feature To Protect Turbocharger When Vehicle Is Not Moving OVERVIEW: This bulletin involves a discussion regarding an engine control feature that limits engine off-idle speeds when the vehicle is not moving. MODELS: 2004 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 5.9L or a 6.7L Cummins turbo-diesel engine (sale codes: ETC, ETH, or ETJ). DISCUSSION: Dependent upon engine coolant temperature, the Engine Control Module (ECM) will temporarily delay (limit) the maximum engine speed when the vehicle is not moving. For automatic transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph, and when the transmission selector is in either the neutral or park position. For manual transmission equipped vehicles, the maximum engine speed is temporarily delayed when the vehicle speed is less than one mph. This ECM feature is used to protect the engine turbocharger. By temporarily limiting the vehicle engine speed, the shaft speed of the engine turbocharger is controlled to a low speed. This delay in maximum engine and turbo-charger shaft speed allows for sufficient oil lubrication to the turbocharger shaft bearings. Satisfactory oil lubrication of the turbocharger shaft bearings is important for long term turbocharger durability. The maximum engine speed for the 5.9L engine is temporarily limited to 1,600 RPM's when the above conditions are met. The 6.7L engine speed is temporarily limited to 1,200 RPM's when the above conditions are met. The length of time that the maximum engine speed is temporarily limited is dependent upon engine coolant temperature. Refer to the table to determine the amount of Time Delay. NOTE: The time delay values supplied in the table are an approximation and may vary per application. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Engine Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 6018 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 6019 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 6020 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness Technical Service Bulletin # K01 Date: 100510 Recall - ECM Update For OBD Readiness May 2010 Dealer Service Instructions for: California Emissions Recall K01 Reprogram ECM OBD Readiness Effective immediately all repairs on involved vehicles are to be performed according to this notification. Service Bulletin 18-038-09 is no longer applicable for the involved vehicles only. Models 2003 (DR) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETC) and a California emission control system (sales code NAE). 2006-2007 (DH/D1) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETH) and a California emission control system (sales code NAE). 2007 (DC) Dodge Ram Truck (3500 series cab chassis) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ) and a California emission control system (sales code NAE) built through January 5, 2007 (MDH010508). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process or GRS DealerCONNECT functions. Subject The Engine Control Module (ECM) on about 25,208 of the above vehicles may fail to accurately report diagnostic system information with some generic scan tools. This may cause the vehicle to be rejected or fail an Inspection/Maintenance Test (also known as a Smog Check). Repair The Engine Control Module (ECM) must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Part Number Description 04275086AB Authorized Modifications Label Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 6026 The special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the label plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 6027 To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: The DRBIII(R) must be used to perform this recall on 2003 Model Year (MY) vehicles. The 2003 MY procedure is found in Section D of the Service Procedure. Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall on 2006-2007 MY vehicles. This procedure must be performed with software release level 10.03 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 6028 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's" button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section E. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 6029 h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section E. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 6030 e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 10. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 9. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 10. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 11. Continue with Section E. Install Authorized Modification Label. D. Reprogram the ECM Using DRBIII(R): The DealerCONNECT System, DRBIII(R) (Diagnostic Readout Box scan tool), CH7000A flash cable and CH7035B data cable are required to perform this repair. Do not attempt to perform the flash procedure using an outdated CH7000/CH7001 flash cable. NOTE: Whenever a controller is reprogrammed, the software in the DRBIII scan tool must be programmed with the latest revision level available. NOTE: If the flash process is interrupted or aborted, the flash should be restarted and then follow the directions on the DRBIII scan tool. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 6031 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the DRBIII CH7000A flash cable from the DRBIII scan tool to the data link connector located inside the vehicle under the steering column. 3. Connect the CH7035B data cable from the DealerCONNECT machine to the MDS port on the DRBIII scan tool. 4. Place the vehicle's ignition key in the "RUN" position. 5. From the DealerCONNECT "WELCOME" screen, enter your "User I.D.," "Password" and "Dealer Code". 6. From the DealerCONNECT "HOME PAGE" select the "SERVICE" tab. 7. From the "SERVICE" tab screen select "TechTOOLS". 8. If the DRBIII scan tool does not "Auto Connect" select # 2 on the DRBIII key pad "Connect to TechCONNECT". 9. After the "Auto Connect" process is complete, select "READ PART NUMBER(S) FROM VEHICLE" on the TechCONNECT screen. 10. Continue following the TechCONNECT on-screen instructions. 11. Select the applicable update calibration. 12. Select the "DRBIII" button located at the bottom of the TechCONNECT monitor screen. 13. Select the "DOWNLOAD / UPDATE" button located next to the "DRBIII" button. NOTE: The system software will automatically download to the DRBIII scan tool. 14. After the software download to the DRBIII scan tool is complete, close the "DOWNLOAD / UPDATE PROGRESS" window. 15. Disconnect the DRBIII scan tool from the TechCONNECT CH7035B data cable. 16. Select # 1 "RETURN TO NORMAL MODE" on the DRBIII scan tool. 17. Use the following procedure to download the flash from the DRBIII scan tool to the vehicle. a. Select # 7 "VEHICLE FLASH" on the DRBIII scan tool. b. Follow the directions displayed on the DRBIII scan tool screen. c. After the reprogramming is complete, record the new module part number displayed on the DRBIII scan tool screen. d. Press the "PAGE BACK" button on the DRBIII scan tool. 18. Due to the ECM flash procedure, Diagnostic Trouble Codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS, ORC) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules, record the trouble codes, and erase the trouble codes using the following procedure: a. Turn the vehicle's ignition key to the "RUN" position. b. From the DRBIII scan tool Main Menu select # 1 "DRBIII Stand-Alone". c. From the DRBIII scan tool Stand-Alone menu select # 3 "Vehicle Module Scan". d. From the DRBIII scan tool Vehicle Module Scan menu select # 1 "1998 - 2005 Module Scan". e. Select "YES" on the DRBIII scan tool key pad to scan for DTC's. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 6032 f. Follow the instructions on the DRBIII scan tool screen. g. Once the scanning process is complete, the DRBIII scan tool will display a list of all the modules. Modules on the list that have an asterisk next to them have DTC's that need to be cleared. h. Select the module that needs to have the DTC's cleared and follow the instructions on the DRBIII scan tool screen to clear the DTC's. i. Turn the vehicle's ignition key to the "OFF" position. NOTE: Erase any DTC's in the ECM only after all other modules have had their DTC's erased. 19. Disconnect the DRBIII scan tool from the vehicle. 20. Turn off the battery charger and disconnect it from the vehicle. 21. Continue with Section E. Install Authorized Modification Label. E. Install the Authorized Modifications Label: 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 6033 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 6038 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 6039 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 6040 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 6041 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 6042 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 6043 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 6044 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 6053 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 6054 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 6055 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control Engine Control Module: Locations Module-Engine Control Component ID: 203 Component : MODULE-ENGINE CONTROL Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (5.9L) Pin Description Circuit 1 WASTEGATE SOLENOID CONTROL K139 18DB 2 OIL PRESSURE SIGNAL G6 18VT/GY 3-4 CAN C BUS (+) D65 18WT/LG 5 CAN C BUS (-) D64 18WT/LB 6 FUEL CONTROL ACTUATOR RETURN K65 18BR/LB 7 GEN FIELD CONTROL K20 18BR/GY 8 TTVA MOTOR (+) K314 18TN/YL 9-10 - 11 WATER IN FUEL SENSOR GROUND K923 18BR/WT 12 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 13 INLET AIR TEMPERATURE SENSE K615 18VT/WT 14 - 15 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 16 INLET AIR PRESSURE SENSE K616 18BR/YL 17 ECT SIGNAL K2 18VT/OR 18 - 19 FUEL CONTROL ACTUATOR DRIVER K604 18BR/TN 20 TTVA MOTOR (-) K315 18TN/OR 21 FAN SPEED SENSOR GROUND K161 18BR/LB 22 CKP SIGNAL K24 18BR/LB 23 SENSOR GROUND K200 18BR/YL 24 CMP SIGNAL K44 18DB/GY 25 5 VOLT SUPPLY K668 18BR 26 - 27 5 VOLT SUPPLY K853 18DB/BR 28 - 29 SENSOR GROUND K690 18BR/YL 30 INJECTOR CONTROL NO. 1 K11 16BR/YL 31 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG 32 CMP SENSOR GROUND K944 18BK/GY Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6058 33 APPS NO. 1 RETURN K167 18BR/YL 34 FAN SPEED SENSOR SIGNAL N210 18DB/DG 35 - 36 INJECTOR CONTROL NO. 4 K14 16BR/TN 37 - 38 - 39 - 40 INJECTOR CONTROL NO. 3 K13 16TN 41 SENSOR GROUND K210 18DB/TN 42 5 VOLT SUPPLY K852 18BR/VT 43 BOOST PRESSURE SENSOR SIGNAL K37 18LB 44 - 45 - 46 INJECTOR CONTROL NO. 6 K58 16BR/VT 47 - 48 - 49 - 50 INJECTOR CONTROL NO. 2 K12 16BR/DB 51 - 52 CKP SENSOR GROUND K975 18BR/OR 53 FUEL RAIL SENSOR RETURN K915 18BR/WT 54 5 VOLT SUPPLY F855 18PK/YL 55 - 56 INJECTOR CONTROL NO. 5 K38 16GY 57 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 16TN/PK 58 - 59 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 16BR/LG 60 - Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6059 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6060 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6061 Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 2 EGR CONTROL NO. 1 K682 18DB/WT 3 EGR CONTROL NO. 2 K684 18DB/YL 4 EGR CONTROL NO. 3 K686 18GY/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6062 5 EGR SIGNAL NO. 2 K685 18DB 6-7 FAN SPEED SENSOR GROUND K161 18BR/LB 8-9 EGR BYPASS VALVE SIGNAL K670 18BR/LB 10 FUEL CONTROL ACTUATOR RETURN K366 18BR/LB 11 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 12 - 13 EGR AIRFLOW CONTROL VALVE MOTOR (-) K314 18BR 14 CRANKCASE SENSOR SIGNAL K926 18DB/GY 15 ECT SIGNAL K2 18VT/OR 16 - 17 EGR BYPASS STATUS K671 18BR/DB 18 FAN SPEED SENSOR SIGNAL N27 18DB/GY 19 BOOST PRESSURE SENSOR SIGNAL K37 18BR 20 INLET AIR PRESSURE SENSE K616 18BR/YL 21 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 22 SENSOR GROUND K971 18BR/PK 23 - 24 INLET AIR TEMPERATURE SENSE K615 18VT/WT 25 EGR SIGNAL NO. 1 K683 18DB/GY 26 5 VOLT SUPPLY K824 18DB/BR 27 EGR AIRFLOW CONTROL VALVE MOTOR (+) K158 18BR/YL 28 GEN SENSE A804 18RD 29 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 30 FUEL CONTROL ACTUATOR DRIVER K365 18DB/BR 31 CKP SIGNAL K24 18BR/LB 32 OIL PRESSURE SIGNAL G6 18VT/GY 33 ACTUATOR GROUND K972 18DB/TN 34 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG 35 EGR SIGNAL NO. 3 K687 18DB/LB 36 5 VOLT SUPPLY F855 18PK/YL 37 CMP SIGNAL K44 18DB/GY 38 ACTUATOR HIGH DATA LINK D130 18BR/VT 39 ACTUATOR LOW DATA LINK D131 18WT/LG 40 GEN FIELD CONTROL K20 18BR/GY 41 EGR TEMPERATURE SENSOR SIGNAL K935 18DB 42 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 43 TURBO SPEED SENSOR GROUND K541 18BR/VT 44 CKP SENSOR GROUND K925 18BR/OR 45 INJECTOR CONTROL NO. 6 K58 16BR/VT 46 INJECTOR CONTROL NO. 2 K12 16BR/DB 47 SENSOR GROUND K914 18BR/WT 48 SENSOR GROUND K916 18BR/OR 49 - 50 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG 51 INJECTOR HIGH SIDE DRIVER NO. 3 K613 16GY/BR 52 INJECTOR HIGH SIDE DRIVER NO. 2 K612 16YL/BR 53 INJECTOR HIGH SIDE DRIVER NO. 1 K611 16OR/BR 54 INJECTOR CONTROL NO. 4 K14 16BR/TN 55 INJECTOR CONTROL NO. 5 K38 16GY 56 INJECTOR CONTROL NO. 3 K13 16TN 57 INJECTOR CONTROL NO. 1 K11 16BR/YL 58 INJECTOR HIGH SIDE DRIVER NO. 6 K658 16LG/BR 59 INJECTOR HIGH SIDE DRIVER NO. 5 K638 16LB/BR 60 INJECTOR HIGH SIDE DRIVER NO. 4 K614 16WT/BR Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6063 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6064 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6065 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 50 Qualifier : (5.9L) Pin Description Circuit 1-2-3 APPS NO. 1 SIGNAL K23 18BR/WT 4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6066 5 TRANSMISSION CONTROL T515 18YL/DB 6 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 7 FUEL PUMP CONTROL K31 18BR 8-9 TRS T41 SIGNAL (P/N) T41 18YL/DB 10 - 11 - 12 - 13 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 18DG 14 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 15 3-4 SOLENOID CONTROL T9 18DG/TN 16 - 17 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 18 - 19 - 20 FUSED B(+) A209 16RD 21 GROUND Z902 16BK 22 - 23 5 VOLT SUPPLY F856 18YL/PK 24 SENSOR GROUND K900 18DB/DG 25 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 26 - 27 TTVA POSITION SENSOR SIGNAL K312 18OR 28 - 29 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR 30 FUSED B(+) A209 16RD 31 - 32 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 33 5 VOLT SUPPLY K854 18VT/BR 34 - 35 APPS NO. 2 SIGNAL K29 18WT/BR 36 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 37 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 38 - 39 - 40 FUSED B(+) A209 16RD 41 A/C CLUTCH CONTROL C13 18LB/OR 42 - 43 PWM FAN COIL SIGNAL K160 18BR/OR 44 OUTPUT SPEED SIGNAL T14 18DG/BR 45 SPEED SENSOR GROUND T13 18DG/VT 46 S/C SWITCH NO. 1 SIGNAL V37 18VT 47 BATT TEMP SIGNAL K25 18DB/VT 48 APPS NO. 2 RETURN K400 18BR/VT 49 GROUND Z902 16BK 50 GROUND Z902 16BK Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6067 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6068 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6069 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 CAN C BUS (+) D65 18WT/LG 2 FUEL PUMP CONTROL K31 18BR 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6070 5 EXHAUST BRAKE SWITCH SIGNAL G905 18BR/OR 6 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 7 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 8 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 9 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/OR 10 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 11 - 12 - 13 - 14 - 15 CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT T26 18DG/OR 16 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 17 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 18 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 19 - 20 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 21 CAN C BUS (-) D64 18WT/LB 22 APPS NO. 2 RETURN K400 18BR/VT 23 - 24 APPS NO. 2 SIGNAL K29 18WT/BR 25 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 26 5 VOLT SUPPLY K854 18VT/BR 27 5 VOLT SUPPLY K852 18BR/LB 28 APPS NO. 1 RETURN K167 18BR/DG 29 SENSOR GROUND K900 18DB/DG 30 BATT TEMP SIGNAL K25 18DB/VT 31 DIAGNOSTIC PORT HIGH DATA LINK D133 18WT/OR 32 - 33 S/C SWITCH RETURN V937 18VT/BR 34 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 35 APPS NO. 1 SIGNAL K23 18BR/WT 36 - - 37 REMOTE THROTTLE SIGNAL K128 18DG/LG 38 - 39 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 40 S/C SWITCH NO. 1 SIGNAL V37 18VT 41 - 42 - 43 SMART POWER RELAY RETURN K348 18BR 44 A/C CLUTCH CONTROL C13 18LB 45 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 46 - 47 GROUND Z902 16BK 48 GROUND Z902 16BK 49 FUSED B(+) A209 16RD 50 FUSED B(+) A209 16RD 51 DIAGNOSTIC PORT LOW DATA LINK D132 18WT 52 - 53 - 54 EXHAUST BRAKE LAMP SIGNAL G904 18VT/DG 55 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 56 S/C SWITCH NO. 2 SIGNAL V38 18VT/OR 57 GROUND Z902 16BK 58 - 59 - 60 FUSED B(+) A209 16RD Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6071 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6072 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6073 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6074 Engine Control Module: Locations Module-Powertrain Control Component ID: 209 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Pin Description Circuit 123456- 789-10 11 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (RUN-START) F1 20PK/WT 13 14 15 16 17 18 - 19 SENSOR GROUND T160 20DG/WT 20 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 21 22 23 24 25 26 - 27 5 VOLT SUPPLY F856 20YL/PK 28 29 FUSED B(+) A918 20RD 30 IGNITION START T751 20YL 31 32 - Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6075 33 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 38 Component Location - 29 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6076 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 8 K98 18DB/YL 2-3 COIL CONTROL NO. 7 K97 18DB/YL 3 COIL CONTROL NO. 7 K97 18BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6077 4 INJECTOR CONTROL NO. 8 K28 18BR/LB 5 INJECTOR CONTROL NO. 7 K26 18BR/YL 6-7-8-9 GROUND Z130 16BK/BR 10 FUSED B(+) A918 16RD 11 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 13 - 14 - 15 - 16 - 17 - 18 GROUND Z131 16BK/DG 19 GROUND Z951 16BK/YL 20 OIL PRESSURE SIGNAL G6 16VT/GY 21 - 22 - 23 - 24 GEN SENSE A804 18RD/GY 25 - 27 5 VOLT SUPPLY F856 20YL/PK 28 MDS SOL CONTROL NO. 4 K452 20BR/LB 29 FUSED B(+) A918 16RD 30 IGNITION START T751 20YL 31 O2 1/2 SIGNAL K141 20DB/YL 32 O2 1/1 RETURN K902 20BR/DG 33 O2 2/2 SIGNAL K243 20BR 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 - - 38 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6078 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6079 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 6 K10 18DB/OR 2 COIL CONTROL NO. 5 K16 18DB/YL 3 COIL CONTROL NO. 4 K15 18DB/GY 4 INJECTOR CONTROL NO. 6 K58 18BR/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6080 5 INJECTOR CONTROL NO. 5 K38 18BR/OR 6 ETC MOTOR (+) K447 20TN/YL 7 COIL CONTROL NO. 3 K18 18DB/OR 8 EGR SOL CONTROL K35 20DB/VT 9 COIL CONTROL NO. 2 K17 18DB/TN 10 COIL CONTROL NO. 1 K19 18DB/DG 11 INJECTOR CONTROL NO. 4 K14 18BR/TN 12 INJECTOR CONTROL NO. 3 K13 18BR/LB 13 INJECTOR CONTROL NO. 2 K12 18BR/DB 14 INJECTOR CONTROL NO. 1 K11 18BR/YL 15 TP SENSOR RETURN K922 20BR/DB 16 MDS SOL CONTROL NO. 6 K453 20BR/DG 17 O2 2/1 HEATER CONTROL K199 20BR/VT 18 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 19 GEN FIELD CONTROL K20 18BR/GY 20 ECT SIGNAL K2 20VT/OR 21 TP NO. 1 SIGNAL K22 20BR/OR 22 EGR SIGNAL K34 20DB/LG 23 MAP SIGNAL K1 20VT/BR 24 KNOCK SENSOR NO. 1 RETURN K942 20BR/LG 25 KNOCK SENSOR NO. 1 SIGNAL K42 20DB/YL 26 - 27 SENSOR GROUND K900 20DB/DG 28 TP NO. 2 SIGNAL K122 20BR/DG 28 IAC SIGNAL K961 20BR/VT 29 5 VOLT SUPPLY F855 20PK/YL 30 IAT SIGNAL K21 20DB/LG 31 O2 1/1 SIGNAL K41 20DB/LB 32 O2 1/2 RETURN K904 20DB/DG 33 O2 2/1 SIGNAL K43 20DB/LG 34 CMP SIGNAL K44 20DB/GY 35 CKP SIGNAL K24 20BR/LB 36 KNOCK SENSOR NO. 2 SIGNAL K242 20BR/WT 37 KNOCK SENSOR NO. 2 RETURN K924 20WT/BR 38 ETC MOTOR (-) K448 20TN/OR 38 IAC CONTROL K61 20VT/GY Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6081 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6082 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1-2-3 ASD CONTROL K51 20BR/WT 4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6083 5 S/C VENT SOL CONTROL V35 20VT/OR 5 MDS SOL CONTROL NO. 7 K454 20BR/OR 6 MDS SOL CONTROL NO. 1 K451 20BR/WT 7 SPEED CONTROL SUPPLY V32 20VT/YL 8-9 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 10 O2 2/2 HEATER CONTROL K399 18BR/GY 11 A/C CLUTCH CONTROL C13 20LB/OR 12 S/C VACUUM SOL CONTROL V36 20VT/YL 13 - 14 BRAKE SWITCH NO. 2 SIGNAL V32 20VT/YL 15 S/C SWITCH RETURN V937 20VT/BR 16 APPS NO. 1 RETURN K167 20BR/YL 17 APPS NO. 2 RETURN K400 20BR/VT 18 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 19 ASD CONTROL OUTPUT K342 16BR/WT 20 EVAP PURGE SOL CONTROL K52 20DB/WT 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 PTO SENSE G113 20VT 22 PTO SENSE G113 18PK/YL 23 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT 24 - 25 APPS NO. 1 SIGNAL K23 20BR/WT 26 - 27 - 28 ASD CONTROL OUTPUT K342 16BR/WT 29 EVAP PURGE SOL SIGNAL K70 20DB/BR 30 P/S SWITCH SIGNAL K66 20DB/WT 31 - 32 - 33 OIL TEMPERATURE SIGNAL G24 20VT/BR 34 S/C SWITCH NO. 1 SIGNAL V37 20VT 35 ESM SIGNAL K107 20VT/WT 36 APPS NO. 2 SIGNAL K29 20WT/BR 37 FUEL PUMP CONTROL K31 20BR 38 STARTER SOLENOID CONTROL T752 20DG/OR Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6084 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6085 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Description Circuit 1 SENSOR GROUND T160 20YL/GY 2 4C CONTROL T259 20YL/DG 34 MS CONTROL T140 20YL/GY Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6086 5- 6 2C CONTROL T219 20YL/LG 78 UD CONTROL T59 20YL/LB 910 L/R CONTROL T20 20DG/BK 11 LINE PRESSURE CONTROL T118 20DG 12 GROUND Z133 18BK/LG 13 GROUND Z133 18BK/LG 14 GROUND Z133 18BK/LG 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 24 25 26 TRS T2 SIGNAL T4 20DG/LB 27 TRS T41 SIGNAL (P/N) T41 20YL/DB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6087 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6088 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 OD SOLENOID CONTROL T60 20YL/GY 2 4C CONTROL T259 20YL/DG 2 UD CONTROL T59 20YL/LB 3-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6089 4 MS CONTROL T140 20YL/GY 5-6 2C CONTROL T219 20YL/LG 6 2-4 SOLENOID CONTROL T19 18YL/DB 7-8 UD CONTROL T59 20YL/LB 9-10 L/R CONTROL T20 20DG/WT 11 PRESSURE CONTROL SOLENOID CONTROL T118 20DG 12 GROUND Z908 18BK 13 GROUND Z977 18BK 14 GROUND Z904 18BK 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 - 24 - 25 - 26 TRS T2 SIGNAL T4 20DG/LB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 30 2-4 PRESSURE SWITCH SENSE T47 18YL/DG 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6090 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 6091 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6094 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6095 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6096 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6097 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6098 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6099 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6100 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6101 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6102 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6103 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6104 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6105 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6106 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6107 Engine Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6108 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6109 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6110 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6111 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6112 Engine Control Module: Connector Views Module-Engine Control Component ID: 203 Component : MODULE-ENGINE CONTROL Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (5.9L) Pin Description Circuit 1 WASTEGATE SOLENOID CONTROL K139 18DB 2 OIL PRESSURE SIGNAL G6 18VT/GY 3-4 CAN C BUS (+) D65 18WT/LG 5 CAN C BUS (-) D64 18WT/LB 6 FUEL CONTROL ACTUATOR RETURN K65 18BR/LB 7 GEN FIELD CONTROL K20 18BR/GY 8 TTVA MOTOR (+) K314 18TN/YL 9-10 - 11 WATER IN FUEL SENSOR GROUND K923 18BR/WT 12 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 13 INLET AIR TEMPERATURE SENSE K615 18VT/WT 14 - 15 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 16 INLET AIR PRESSURE SENSE K616 18BR/YL 17 ECT SIGNAL K2 18VT/OR 18 - 19 FUEL CONTROL ACTUATOR DRIVER K604 18BR/TN 20 TTVA MOTOR (-) K315 18TN/OR 21 FAN SPEED SENSOR GROUND K161 18BR/LB 22 CKP SIGNAL K24 18BR/LB 23 SENSOR GROUND K200 18BR/YL 24 CMP SIGNAL K44 18DB/GY 25 5 VOLT SUPPLY K668 18BR 26 - 27 5 VOLT SUPPLY K853 18DB/BR 28 - 29 SENSOR GROUND K690 18BR/YL 30 INJECTOR CONTROL NO. 1 K11 16BR/YL 31 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6113 32 CMP SENSOR GROUND K944 18BK/GY 33 APPS NO. 1 RETURN K167 18BR/YL 34 FAN SPEED SENSOR SIGNAL N210 18DB/DG 35 - 36 INJECTOR CONTROL NO. 4 K14 16BR/TN 37 - 38 - 39 - 40 INJECTOR CONTROL NO. 3 K13 16TN 41 SENSOR GROUND K210 18DB/TN 42 5 VOLT SUPPLY K852 18BR/VT 43 BOOST PRESSURE SENSOR SIGNAL K37 18LB 44 - 45 - 46 INJECTOR CONTROL NO. 6 K58 16BR/VT 47 - 48 - 49 - 50 INJECTOR CONTROL NO. 2 K12 16BR/DB 51 - 52 CKP SENSOR GROUND K975 18BR/OR 53 FUEL RAIL SENSOR RETURN K915 18BR/WT 54 5 VOLT SUPPLY F855 18PK/YL 55 - 56 INJECTOR CONTROL NO. 5 K38 16GY 57 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 16TN/PK 58 - 59 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 16BR/LG 60 - Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6114 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6115 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6116 Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 2 EGR CONTROL NO. 1 K682 18DB/WT 3 EGR CONTROL NO. 2 K684 18DB/YL 4 EGR CONTROL NO. 3 K686 18GY/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6117 5 EGR SIGNAL NO. 2 K685 18DB 6-7 FAN SPEED SENSOR GROUND K161 18BR/LB 8-9 EGR BYPASS VALVE SIGNAL K670 18BR/LB 10 FUEL CONTROL ACTUATOR RETURN K366 18BR/LB 11 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 12 - 13 EGR AIRFLOW CONTROL VALVE MOTOR (-) K314 18BR 14 CRANKCASE SENSOR SIGNAL K926 18DB/GY 15 ECT SIGNAL K2 18VT/OR 16 - 17 EGR BYPASS STATUS K671 18BR/DB 18 FAN SPEED SENSOR SIGNAL N27 18DB/GY 19 BOOST PRESSURE SENSOR SIGNAL K37 18BR 20 INLET AIR PRESSURE SENSE K616 18BR/YL 21 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 22 SENSOR GROUND K971 18BR/PK 23 - 24 INLET AIR TEMPERATURE SENSE K615 18VT/WT 25 EGR SIGNAL NO. 1 K683 18DB/GY 26 5 VOLT SUPPLY K824 18DB/BR 27 EGR AIRFLOW CONTROL VALVE MOTOR (+) K158 18BR/YL 28 GEN SENSE A804 18RD 29 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 30 FUEL CONTROL ACTUATOR DRIVER K365 18DB/BR 31 CKP SIGNAL K24 18BR/LB 32 OIL PRESSURE SIGNAL G6 18VT/GY 33 ACTUATOR GROUND K972 18DB/TN 34 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG 35 EGR SIGNAL NO. 3 K687 18DB/LB 36 5 VOLT SUPPLY F855 18PK/YL 37 CMP SIGNAL K44 18DB/GY 38 ACTUATOR HIGH DATA LINK D130 18BR/VT 39 ACTUATOR LOW DATA LINK D131 18WT/LG 40 GEN FIELD CONTROL K20 18BR/GY 41 EGR TEMPERATURE SENSOR SIGNAL K935 18DB 42 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 43 TURBO SPEED SENSOR GROUND K541 18BR/VT 44 CKP SENSOR GROUND K925 18BR/OR 45 INJECTOR CONTROL NO. 6 K58 16BR/VT 46 INJECTOR CONTROL NO. 2 K12 16BR/DB 47 SENSOR GROUND K914 18BR/WT 48 SENSOR GROUND K916 18BR/OR 49 - 50 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG 51 INJECTOR HIGH SIDE DRIVER NO. 3 K613 16GY/BR 52 INJECTOR HIGH SIDE DRIVER NO. 2 K612 16YL/BR 53 INJECTOR HIGH SIDE DRIVER NO. 1 K611 16OR/BR 54 INJECTOR CONTROL NO. 4 K14 16BR/TN 55 INJECTOR CONTROL NO. 5 K38 16GY 56 INJECTOR CONTROL NO. 3 K13 16TN 57 INJECTOR CONTROL NO. 1 K11 16BR/YL 58 INJECTOR HIGH SIDE DRIVER NO. 6 K658 16LG/BR 59 INJECTOR HIGH SIDE DRIVER NO. 5 K638 16LB/BR 60 INJECTOR HIGH SIDE DRIVER NO. 4 K614 16WT/BR Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6118 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6119 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6120 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 50 Qualifier : (5.9L) Pin Description Circuit 1-2-3 APPS NO. 1 SIGNAL K23 18BR/WT 4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6121 5 TRANSMISSION CONTROL T515 18YL/DB 6 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 7 FUEL PUMP CONTROL K31 18BR 8-9 TRS T41 SIGNAL (P/N) T41 18YL/DB 10 - 11 - 12 - 13 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 18DG 14 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 15 3-4 SOLENOID CONTROL T9 18DG/TN 16 - 17 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 18 - 19 - 20 FUSED B(+) A209 16RD 21 GROUND Z902 16BK 22 - 23 5 VOLT SUPPLY F856 18YL/PK 24 SENSOR GROUND K900 18DB/DG 25 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 26 - 27 TTVA POSITION SENSOR SIGNAL K312 18OR 28 - 29 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR 30 FUSED B(+) A209 16RD 31 - 32 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 33 5 VOLT SUPPLY K854 18VT/BR 34 - 35 APPS NO. 2 SIGNAL K29 18WT/BR 36 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 37 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 38 - 39 - 40 FUSED B(+) A209 16RD 41 A/C CLUTCH CONTROL C13 18LB/OR 42 - 43 PWM FAN COIL SIGNAL K160 18BR/OR 44 OUTPUT SPEED SIGNAL T14 18DG/BR 45 SPEED SENSOR GROUND T13 18DG/VT 46 S/C SWITCH NO. 1 SIGNAL V37 18VT 47 BATT TEMP SIGNAL K25 18DB/VT 48 APPS NO. 2 RETURN K400 18BR/VT 49 GROUND Z902 16BK 50 GROUND Z902 16BK Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6122 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6123 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6124 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 60 Qualifier : (6.7L) Pin Description Circuit 1 CAN C BUS (+) D65 18WT/LG 2 FUEL PUMP CONTROL K31 18BR 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6125 5 EXHAUST BRAKE SWITCH SIGNAL G905 18BR/OR 6 BRAKE SWITCH NO. 2 SIGNAL V32 18VT/YL 7 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 8 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 9 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/OR 10 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 11 - 12 - 13 - 14 - 15 CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT T26 18DG/OR 16 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 17 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 18 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 19 - 20 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 21 CAN C BUS (-) D64 18WT/LB 22 APPS NO. 2 RETURN K400 18BR/VT 23 - 24 APPS NO. 2 SIGNAL K29 18WT/BR 25 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 26 5 VOLT SUPPLY K854 18VT/BR 27 5 VOLT SUPPLY K852 18BR/LB 28 APPS NO. 1 RETURN K167 18BR/DG 29 SENSOR GROUND K900 18DB/DG 30 BATT TEMP SIGNAL K25 18DB/VT 31 DIAGNOSTIC PORT HIGH DATA LINK D133 18WT/OR 32 - 33 S/C SWITCH RETURN V937 18VT/BR 34 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 35 APPS NO. 1 SIGNAL K23 18BR/WT 36 - - 37 REMOTE THROTTLE SIGNAL K128 18DG/LG 38 - 39 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 40 S/C SWITCH NO. 1 SIGNAL V37 18VT 41 - 42 - 43 SMART POWER RELAY RETURN K348 18BR 44 A/C CLUTCH CONTROL C13 18LB 45 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY 46 - 47 GROUND Z902 16BK 48 GROUND Z902 16BK 49 FUSED B(+) A209 16RD 50 FUSED B(+) A209 16RD 51 DIAGNOSTIC PORT LOW DATA LINK D132 18WT 52 - 53 - 54 EXHAUST BRAKE LAMP SIGNAL G904 18VT/DG 55 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 56 S/C SWITCH NO. 2 SIGNAL V38 18VT/OR 57 GROUND Z902 16BK 58 - 59 - 60 FUSED B(+) A209 16RD Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6126 Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6127 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6128 Module-Powertrain Control Component ID: 209 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6129 Pin Description Circuit 123456789-10 11 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (RUN-START) F1 20PK/WT 13 14 15 16 17 18 - 19 SENSOR GROUND T160 20DG/WT 20 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 21 22 23 24 25 26 - 27 5 VOLT SUPPLY F856 20YL/PK 28 29 FUSED B(+) A918 20RD 30 IGNITION START T751 20YL 31 - 32 33 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 38 Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6130 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6131 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 8 K98 18DB/YL 2-3 COIL CONTROL NO. 7 K97 18DB/YL 3 COIL CONTROL NO. 7 K97 18BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6132 4 INJECTOR CONTROL NO. 8 K28 18BR/LB 5 INJECTOR CONTROL NO. 7 K26 18BR/YL 6-7-8-9 GROUND Z130 16BK/BR 10 FUSED B(+) A918 16RD 11 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 12 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 13 - 14 - 15 - 16 - 17 - 18 GROUND Z131 16BK/DG 19 GROUND Z951 16BK/YL 20 OIL PRESSURE SIGNAL G6 16VT/GY 21 - 22 - 23 - 24 GEN SENSE A804 18RD/GY 25 - 27 5 VOLT SUPPLY F856 20YL/PK 28 MDS SOL CONTROL NO. 4 K452 20BR/LB 29 FUSED B(+) A918 16RD 30 IGNITION START T751 20YL 31 O2 1/2 SIGNAL K141 20DB/YL 32 O2 1/1 RETURN K902 20BR/DG 33 O2 2/2 SIGNAL K243 20BR 34 CAN C BUS (+) D65 20WT/LG 35 CAN C BUS (-) D64 20WT/LB 36 - - 38 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6133 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6134 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 COIL CONTROL NO. 6 K10 18DB/OR 2 COIL CONTROL NO. 5 K16 18DB/YL 3 COIL CONTROL NO. 4 K15 18DB/GY 4 INJECTOR CONTROL NO. 6 K58 18BR/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6135 5 INJECTOR CONTROL NO. 5 K38 18BR/OR 6 ETC MOTOR (+) K447 20TN/YL 7 COIL CONTROL NO. 3 K18 18DB/OR 8 EGR SOL CONTROL K35 20DB/VT 9 COIL CONTROL NO. 2 K17 18DB/TN 10 COIL CONTROL NO. 1 K19 18DB/DG 11 INJECTOR CONTROL NO. 4 K14 18BR/TN 12 INJECTOR CONTROL NO. 3 K13 18BR/LB 13 INJECTOR CONTROL NO. 2 K12 18BR/DB 14 INJECTOR CONTROL NO. 1 K11 18BR/YL 15 TP SENSOR RETURN K922 20BR/DB 16 MDS SOL CONTROL NO. 6 K453 20BR/DG 17 O2 2/1 HEATER CONTROL K199 20BR/VT 18 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 19 GEN FIELD CONTROL K20 18BR/GY 20 ECT SIGNAL K2 20VT/OR 21 TP NO. 1 SIGNAL K22 20BR/OR 22 EGR SIGNAL K34 20DB/LG 23 MAP SIGNAL K1 20VT/BR 24 KNOCK SENSOR NO. 1 RETURN K942 20BR/LG 25 KNOCK SENSOR NO. 1 SIGNAL K42 20DB/YL 26 - 27 SENSOR GROUND K900 20DB/DG 28 TP NO. 2 SIGNAL K122 20BR/DG 28 IAC SIGNAL K961 20BR/VT 29 5 VOLT SUPPLY F855 20PK/YL 30 IAT SIGNAL K21 20DB/LG 31 O2 1/1 SIGNAL K41 20DB/LB 32 O2 1/2 RETURN K904 20DB/DG 33 O2 2/1 SIGNAL K43 20DB/LG 34 CMP SIGNAL K44 20DB/GY 35 CKP SIGNAL K24 20BR/LB 36 KNOCK SENSOR NO. 2 SIGNAL K242 20BR/WT 37 KNOCK SENSOR NO. 2 RETURN K924 20WT/BR 38 ETC MOTOR (-) K448 20TN/OR 38 IAC CONTROL K61 20VT/GY Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6136 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6137 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1-2-3 ASD CONTROL K51 20BR/WT 4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6138 5 S/C VENT SOL CONTROL V35 20VT/OR 5 MDS SOL CONTROL NO. 7 K454 20BR/OR 6 MDS SOL CONTROL NO. 1 K451 20BR/WT 7 SPEED CONTROL SUPPLY V32 20VT/YL 8-9 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 10 O2 2/2 HEATER CONTROL K399 18BR/GY 11 A/C CLUTCH CONTROL C13 20LB/OR 12 S/C VACUUM SOL CONTROL V36 20VT/YL 13 - 14 BRAKE SWITCH NO. 2 SIGNAL V32 20VT/YL 15 S/C SWITCH RETURN V937 20VT/BR 16 APPS NO. 1 RETURN K167 20BR/YL 17 APPS NO. 2 RETURN K400 20BR/VT 18 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 19 ASD CONTROL OUTPUT K342 16BR/WT 20 EVAP PURGE SOL CONTROL K52 20DB/WT 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 PTO SENSE G113 20VT 22 PTO SENSE G113 18PK/YL 23 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT 24 - 25 APPS NO. 1 SIGNAL K23 20BR/WT 26 - 27 - 28 ASD CONTROL OUTPUT K342 16BR/WT 29 EVAP PURGE SOL SIGNAL K70 20DB/BR 30 P/S SWITCH SIGNAL K66 20DB/WT 31 - 32 - 33 OIL TEMPERATURE SIGNAL G24 20VT/BR 34 S/C SWITCH NO. 1 SIGNAL V37 20VT 35 ESM SIGNAL K107 20VT/WT 36 APPS NO. 2 SIGNAL K29 20WT/BR 37 FUEL PUMP CONTROL K31 20BR 38 STARTER SOLENOID CONTROL T752 20DG/OR Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6139 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6140 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Description Circuit 1 SENSOR GROUND T160 20YL/GY 2 4C CONTROL T259 20YL/DG 34 MS CONTROL T140 20YL/GY Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6141 5- 6 2C CONTROL T219 20YL/LG 78 UD CONTROL T59 20YL/LB 910 L/R CONTROL T20 20DG/BK 11 LINE PRESSURE CONTROL T118 20DG 12 GROUND Z133 18BK/LG 13 GROUND Z133 18BK/LG 14 GROUND Z133 18BK/LG 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 24 25 26 TRS T2 SIGNAL T4 20DG/LB 27 TRS T41 SIGNAL (P/N) T41 20YL/DB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6142 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6143 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Description Circuit 1 OD SOLENOID CONTROL T60 20YL/GY 2 4C CONTROL T259 20YL/DG 2 UD CONTROL T59 20YL/LB 3-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6144 4 MS CONTROL T140 20YL/GY 5-6 2C CONTROL T219 20YL/LG 6 2-4 SOLENOID CONTROL T19 18YL/DB 7-8 UD CONTROL T59 20YL/LB 9-10 L/R CONTROL T20 20DG/WT 11 PRESSURE CONTROL SOLENOID CONTROL T118 20DG 12 GROUND Z908 18BK 13 GROUND Z977 18BK 14 GROUND Z904 18BK 15 TRS T1 SIGNAL T1 20DG/LB 16 TRS T3 SIGNAL T3 20DG/DB 17 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 18 TRANSMISSION CONTROL T515 20YL/DB 19 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 20 4C PRESSURE SIGNAL T48 20BR/YL 21 UD PRESSURE SIGNAL T29 20YL/WT 22 OD PRESSURE SIGNAL T9 20DG/TN 23 - 24 - 25 - 26 TRS T2 SIGNAL T4 20DG/LB 28 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 29 L/R PRESSURE SIGNAL T50 20DG/PK 30 2C PRESSURE SIGNAL T147 20DG/YL 30 2-4 PRESSURE SWITCH SENSE T47 18YL/DG 31 LINE PRESSURE SIGNAL T38 20YL/BR 32 OUTPUT SPEED SIGNAL T14 20DG/BR 33 INPUT SPEED SIGNAL T52 20DG/OR 34 SPEED SENSOR GROUND T13 20DG/VT 35 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 36 - 37 TRS T42 SIGNAL T42 20DG/YL 38 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6145 Component Location - 6 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6146 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description Engine Control Module: Description and Operation Description DESCRIPTION CUMMINS FUEL SYSTEM COMPONENTS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 6149 The Engine Control Module (ECM) for the 5.9L diesel engine (16) is bolted to the left side of the engine below the intake manifold. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 6150 Engine Control Module: Description and Operation Operation OPERATION The main function of the Engine Control Module (ECM) is to electrically control the fuel system. The ECM also controls certain transmission and other functions previously controlled by the Powertrain Control Module (PCM). The ECM can adapt its programming to meet changing operating conditions. The ECM receives input signals from various switches and sensors. Based on these inputs, the ECM regulates various engine and vehicle operations through different system components. These components are referred to as ECM Outputs. The sensors and switches that provide inputs to the ECM are considered ECM Inputs. NOTE: ECM Inputs: - Accelerator Pedal Position Sensor (APPS) Signals #1 and #2 - AC system pressure - Auto shutdown (ASD) sense - Battery temperature - Battery temperature sensor - Battery voltage - Brake switch - Camshaft Position Sensor (CMP) - Crankshaft Position Sensor (CKP) - Data link connection for a scan tool - Engine Coolant Temperature (ECT) sensor - EATX module (if equipped) - Fuel level - Fuel pressure sensor - Fan speed (engine cooling fan) - Generator (battery voltage) output - Governor pressure (Auto. trans.) - Ground circuits - Inlet air temperature sensor/pressure sensor - Intake air temperature sensor/MAP sensor - CAN C BUS (+) circuits - CAN C BUS (-) circuits - Key switch (ignition) - Oil Pressure switch - Overdrive switch (automatic transmission only) - Park/neutral switch (auto. trans. only) - Power ground - SCI datalink bus (+) circuits - SCI datalink bus (-) circuits - Sensor return - Signal ground - Speed control multiplexed single wire input - Transfer case switch (4WD range position) - Transmission governor psi (automatic transmission only) - Transmission OSS (automatic transmission only) - Transmission oil pressure (automatic transmission only) - Transmission oil temperature (automatic transmission only) - Transmission throttle valve position (automatic transmission only) - Vehicle speed signal - Water-In-Fuel (WIF) sensor NOTE: ECM Outputs: After inputs are received by the ECM, certain sensors, switches and components are controlled or regulated by the ECM. These are considered ECM Outputs. These outputs are for: - A/C clutch relay - Auto shutdown (ASD) relay - Data link connection for diagnostic scan tool - Fan clutch PWM Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 6151 - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel control actuator - Fuel injector driver circuits - Fuel transfer (lift) pump - Generator field driver (-) - Generator field driver (+) - Governor pressure (VFS solenoid) - Intake manifold air heater relays #1 and #2 control circuits - CAN C BUS (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oil pressure switch/warning lamp (databus) - Overdrive/3-4 shift solenoid (automatic transmission only) - SC source - SCI datalink bus (+) circuits - SCI datalink bus (-) circuits - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - TCC solenoid (automatic transmission only) - Transmission battery relay (automatic transmission only) - Transmission throttle valve actuator (automatic transmission only) - Transmission governor solenoid (automatic transmission only) - Wait-to-start warning lamp (databus) - Turbo wastegate solenoid - Water-In-Fuel (WIF) warning lamp (databus) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming Engine Control Module: Testing and Inspection PCM/ECM Programming PCM/ECM REPROGRAMMING MODULE REPROGRAMING Replacement PCM's will require programming utilizing the StarSCAN(R) or equivalent. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. SPECIAL TOOLS/EQUIPMENT OR EQUIVALENT REQUIRED: **REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The StarSCAN(R) or equivalent diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) or equivalent for your dealership's network. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9410 StarSCAN(R) or equivalent ethernet cable to the StarSCAN(R) or equivalent and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 4. Power ON the StarSCAN(R) or equivalent. 5. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. 6. Replace the PCM with the appropriate Generic PCM. 7. Program the PCM as follows: a. Using the StarSCAN(R) or equivalent at the "Home" screen, Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File". Follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 6154 f. Highlight the appropriate calibration based on the part number recorded in Step 5. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. 8. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 9. b. No >> go to STEP 10. 9. Program the PCM to the Wireless Control Module (WCM). a. Highlight the WCM. b. Select "Misc. Function". c. Highlight "PCM Replaced". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step. f. When complete proceed to STEP 11. 10. Program the VIN into the PCM. a. Scroll through the list of controllers and highlight the PCM. b. Select "Misc. Function". c. Highlight "Check PCM VIN". d. Select "Start". e. Follow the on screen instructions. Select "Next" after each step . When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 11. Is the vehicle equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 13. b. No >> go to STEP 12. 12. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select ECU View b. Scroll through the list of controllers and highlight the PCM. c. Select Misc. Function. d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select Next after each step . Select Finish after completing the last step. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the Home screen select System View. Then select All DTCs. Press Clear All Stored DTCs if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label . REPAIR PROCEDURE USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 6155 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 3. Power ON the StarSCAN(R) or equivalent. 4. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. 5. Replace the PCM with the appropriate Generic PCM. 6. Insert the StarSCAN(R) or equivalent Software Update CD into the Techconnect or equivalent PC. The StarSCAN(R) or equivalent Software Update CD will start automatically. Select "Download Flash Updates". 7. At the "Select a method for looking up controller flash updates." screen: a. Select "Enter part number". Enter the "Part Number" recorded in STEP 4 when prompted to do so. b. Using the mouse highlight the appropriate "Calibration". Select "Next". c. Follow the on screen instructions. d. When completed, proceed to STEP 8. 8. With the StarSCAN(R) or equivalent powered OFF, connect the USB Key and Gender Changer to the StarSCAN(R) or equivalent USB port . 9. Connect the StarSCAN(R) or equivalent to the vehicle (if not already connected). 10. Power ON the StarSCAN(R) or equivalent. 11. Download the flash file from the USB key to the StarSCAN(R) or equivalent. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "Flash Download", then select "Retrieve files from the USB storage device" b. Highlight the appropriate calibration. Select "Download to Scan Tool" c. When the download is complete, select "Close" and "Back". 12. Reprogram the ECU. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View". b. Select More Options". c. Select "ECU Flash". d. Highlight the appropriate calibration. e. Select "Update Controller". Follow the on screen instructions. f. When the update is complete, select "OK". g. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 6156 13. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 14. b. No >> go to STEP 15. 14. Program the PCM to the Wireless Control Module (WCM). Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the WCM. c. Select "Misc. Function". d. Highlight "PCM Replaced". e. Select "Start". f. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step. g. When complete proceed to STEP 16. 15. Program the VIN into the PCM. a. Scroll through the list of controllers and highlight the PCM. b. Select "Misc. Function". c. Highlight "Check PCM VIN". d. Select "Start". e. Follow the on screen instructions. Select "Next" after each step . When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 16. Is the vehicle equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 18. b. No >> go to STEP 17. 17. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the PCM. c. Select "Misc. Function". d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "ECU View" from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 18. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label . Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 6157 Engine Control Module: Testing and Inspection SKREEM Programming SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: 1. Program the new PCM/ECM. 2. Program the new SKREEM/WCM. 3. Replace all ignition keys and program them into the new SKREEM/WCM. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Be certain to enter the correct country code for the SKREEM/WCM. If the incorrect country code is programmed into the SKREEM, it cannot be changed and the SKREEM must be replaced. NOTE: In addition, the SKREEM/WCM must be configured for certain optional equipment in the vehicle, including Tire Pressure Monitor (TPM), Remote Keyless Entry (RKE) and Remote Start. Follow the programming steps outlined in the diagnostic scan tool under MISCELLANEOUS FUNCTIONS for the WCM/WIRELESS CONTROL MODULE menu item as appropriate. NOTE: A replacement SKREEM/WCM is supplied with TPM enabled by default; therefore, if the vehicle is not equipped with TPM, the ElectroMechanical Instrument Cluster (EMIC) will incorrectly learn that the vehicle has TPM after the replacement SKREEM is installed. The TPM indicator in the EMIC will illuminate to show a TPM fault condition after TPM has been disabled in the SKREEM. The EMIC must unlearn TPM to correct this false TPM indication. Follow the programming steps outlined in the diagnostic scan tool for CLEAR LEARNED FEATURES under MISCELLANEOUS FUNCTIONS for the INSTRUMENT CLUSTER menu item as appropriate. NOTE: If the PCM/ECM and the SKREEM/WCM are replaced at the same time, all vehicle ignition keys will need to be replaced and the new keys programmed into the new SKREEM/WCM. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > PCM/ECM Programming > Page 6158 Engine Control Module: Testing and Inspection Programming The SKREEM/WCM Using The Scan Tool STANDARD PROCEDURE - PROGRAMMING THE SKREEM/WCM USING THE SCAN TOOL CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the scan tool. CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal Engine Control Module: Service and Repair Removal 6.7L DIESEL The Engine Control Module (ECM) (5) is located on the left side of the engine. A support bracket mounts to the block with four capscrews and vibration isolators. A ground wire is fastened to the bracket. The other end of the wire is fastened to the engine block. 1. Record any Diagnostic Trouble Codes (DTC's) found in the ECM. To avoid possible voltage spike damage to the ECM, ignition key must be off, and both negative battery cables must be disconnected before unplugging ECM connectors. 2. Disconnect both negative battery cables at both batteries. Access to the ECM is easier by working through the left front wheel opening. 3. Remove left front wheel. 4. Remove plastic left front fender splash shield. 5. Remove electrical connector bolts at ECM. Note: As each bolt is being removed, very carefully remove connectors from the ECM. 6. Remove three ECM mounting bolts (6) and remove ECM from engine. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 6161 Engine Control Module: Service and Repair Installation 6.7L DIESEL Do not apply paint to ECM or a poor ground will result. 1. Position ECM (5) to the ECM support bracket and install mounting bolts. Tighten bolts to 24 Nm (18 ft. lbs.). 2. Check pins in electrical connectors for corrosion, damage or dirt intrusion. Also check all pins for being bent. Repair as necessary. Damaged, dirty, bent or corroded pins could result in poor conductivity, causing intermittent electrical issues or DTC's. 3. Clean pins in electrical connectors with an electrical contact cleaner. 4. Install connectors to ECM. Tighten connector bolts to 3 Nm (27 in. lbs.). 5. Install splash shield. 6. Install left front wheel. 7. Connect both negative battery cables. 8. Use a diagnostic scan tool to erase any Diagnostic Trouble Codes (DTC's) from ECM. FUEL INJECTOR ID CORRECTION CODES: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Removal > Page 6162 Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector (1) and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Engine Control Module (ECM) using a diagnostic scan tool. In addition, if a new ECM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new ECM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 6166 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 6167 Main Relay (Computer/Fuel System): Diagrams Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 6168 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 6169 Main Relay (Computer/Fuel System): Testing and Inspection Fig.1 ASD And Fuel Pump Relay Terminals-Type 1 Fig.2 ASD And Fuel Pump Relay Terminals-Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 6170 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Diagrams Oxygen Sensor Relay: Diagrams 2007-2009 Ram truck, 6.7L, use an O2 module for oxygen sensor heater control. The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6178 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6179 Accelerator Pedal Position Sensor: Diagrams Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6180 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 6183 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) provides the Engine Control Module (ECM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 6186 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 6190 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 6191 Air Flow Meter/Sensor: Diagrams Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 6192 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 6193 Air Flow Meter/Sensor: Description and Operation OPERATION The Mass Airflow (MAF) sensor is a frequency based device. A constant voltage is applied to a heated wire on the sensor. This wire is positioned in the air cleaner air stream and is heated by the electrical current that the voltage produces. As air flows across it, it cools down. The heated wire or film is a positive temperature coefficient resistor. This means that its resistance drops when its temperature drops. The drop in resistance allows more current to flow through it in order to maintain the programmed temperature. This current is changed to a frequency which is sent to the Engine Control Module (ECM) and interpreted as air flow. Adjustments for air temperature and humidity are taken into consideration because they also affect the temperature of the heated wire or film. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL The Mass Airflow Sensor (5) is located on the air cleaner cover (8). 1. Disconnect electrical connector (6) at sensor. 2. Remove two mounting screws (4). 3. Remove sensor from air cleaner cover. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 6196 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (4). 4. Install electrical connector (6). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Description and Operation Barometric Pressure Sensor: Description and Operation OPERATION The Inlet Air Temperature/Pressure Sensor is a combination dual-function sensor. The sensor element extends into the intake air stream at the top of the air filter housing. Ambient air temperature as well as barometric pressure is monitored by this sensor. The Engine Control Module (ECM) monitors signals from this sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Service and Repair > Removal Barometric Pressure Sensor: Service and Repair Removal REMOVAL The Inlet Air Temperature/Pressure Sensor (3) is located on the air cleaner cover. 1. Disconnect electrical connector (7) at sensor. 2. Remove mounting screw (2). 3. Remove sensor from air cleaner cover. 4. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Service and Repair > Removal > Page 6202 Barometric Pressure Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor (3) into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (2). 4. Install electrical connector (7). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Component ID: 388 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 BATT TEMP SIGNAL K25 20DB/VT 2 SENSOR GROUND K900 20DB/DG Component Location - 32 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 6206 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 6207 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 6208 Battery Temperature Sensor: Diagrams Component ID: 388 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 BATT TEMP SIGNAL K25 20DB/VT 2 SENSOR GROUND K900 20DB/DG Component Location - 32 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 6209 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 6210 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Description DESCRIPTION The Battery Temperature Sensor (BTS) is used only on the diesel engine. It is attached to the battery tray located under the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description > Page 6213 Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Operation OPERATION The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Removal REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4) . 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3) . 3. Disconnect sensor from engine wire harness electrical connector. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal > Page 6216 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Installation INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 6220 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 6221 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 6222 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 6223 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 6224 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 6225 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 6226 Camshaft Position Sensor: Diagrams Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 6227 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 6228 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 6229 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 6230 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 6231 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 6232 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) is located below the fuel injection pump. It is bolted to the back of the timing gear cover. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 6235 Camshaft Position Sensor: Description and Operation Operation 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) contains a hall effect device. A rotating target wheel (tonewheel) for the CMP is located on the front timing gear. This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CMP. When the leading edge of the tonewheel notch passes the tip of the CMP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CMP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The CMP provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses the CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal Camshaft Position Sensor: Service and Repair Removal 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) on the diesel engine is located below the fuel injection pump (1). It is bolted to the back of the timing gear cover. 1. Disconnect electrical connector (5) at CMP sensor. 2. Remove sensor mounting bolt (6). 3. Carefully twist sensor from timing gear cover. 4. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 6238 Camshaft Position Sensor: Service and Repair Installation 5.9L/6.7L DIESEL The CMP (1) is located on the back of the timing gear cover. 1. Clean out machined hole in back of timing gear cover. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into timing gear cover with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to back of timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in.lbs.). 5. Connect electrical connector to sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Description Coolant Temperature Sensor/Switch (For Computer): Description and Operation Description DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Description > Page 6243 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Operation OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air-fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: - for engine coolant temperature gauge operation through CAN Bus communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid on/off times - Cooling fan control - Temperature gauge operation - A/C cutoff at high coolant temperatures - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Removal Coolant Temperature Sensor/Switch (For Computer): Service and Repair Removal 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL WARNING: Hot, pressurized coolant can cause injury by scalding. Cooling system must be partially drained before removing the coolant temperature sensor. 1. Partially drain the cooling system. ECT LOCATION - 5.9L DIESEL 2. Remove heat shield (if equipped). 3. Disconnect the electrical connector (2) from the ETC sensor (3). 4. Remove the ETC sensor from the cylinder head. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Service and Repair > Removal > Page 6246 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Installation 5.9L/6.7L DIESEL ECT LOCATION - 6.7L DIESEL 1. Install sensor (1 or 3) to engine. 2. Tighten sensor to 18 Nm (13 ft. lbs.) torque. ECT LOCATION - 5.9L DIESEL 3. Connect electrical connector (2) to ETC sensor (1 or 3). 4. Install heat shield (if equipped). 5. Replace any lost engine coolant. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6250 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6251 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6252 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6253 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6254 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6255 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6256 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6257 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6258 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6259 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6260 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6261 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6262 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6263 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6264 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6265 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6266 Crankshaft Position Sensor: Diagrams Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6267 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6268 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6269 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6270 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6271 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6272 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6273 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6274 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6275 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6276 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6277 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6278 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6279 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6280 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6281 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 6282 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The Crankshaft Position Sensor (CKP) on the diesel engine is attached at the front / left side of the engine next to the engine harmonic balancer (crankshaft damper). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 6285 Crankshaft Position Sensor: Description and Operation Operation OPERATION The Crankshaft Position Sensor (CKP) (5) is the primary engine speed indicator for the engine after the engine is running. The CKP contains a hall effect device. A rotating, notched target wheel (tonewheel) (3) for the CKP is attached to the engine harmonic balancer (2). This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CKP. When the leading edge of the tonewheel notch passes the tip of the CKP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CKP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The Camshaft Position Sensor (CMP) also provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses this CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal Crankshaft Position Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle 2. Disconnect electrical connector (4) at CKP sensor. 3. Remove 1 sensor mounting bolt (3). 4. Remove CKP sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 6288 Crankshaft Position Sensor: Service and Repair Installation INSTALLATION 1. Position and install CKP sensor (5) to engine. 2. Install 1 sensor mounting bolt and tighten to 9 Nm (80 in. lbs.) torque. 3. Install electrical connector (4) to CKP sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations Crankcase Pressure Sensor: Locations Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 6292 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 6293 Crankcase Pressure Sensor: Diagrams Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 6294 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 6295 Crankcase Pressure Sensor: Description and Operation OPERATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). The CP sensor monitors crankcase pressure that builds up as the result of combustion gas blow-by. The Engine Control Module (ECM) uses data from the CP sensor to determine the condition of the crankcase breather (ventilation) filter. The ECM can also determine if a crankcase breather (ventilation) filter is present. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal Crankcase Pressure Sensor: Service and Repair Removal REMOVAL The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Remove mounting screw (6). 2. Disconnect electrical connector (7). 3. Remove sensor (5) from valve cover (4). 4. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal > Page 6298 Crankcase Pressure Sensor: Service and Repair Installation INSTALLATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Check condition of sensor O-ring. 2. Install sensor (5) into valve cover (4). 3. Install mounting screw (6). Tighten to 3 Nm (27 in. lbs.) torque. 4. Connect electrical connector (7). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6303 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6304 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6305 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6306 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6307 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6308 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6309 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6310 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6313 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6314 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6315 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6316 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6317 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6318 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6319 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6320 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 6323 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 6326 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 6331 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 6332 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 6333 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 6334 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 6335 Component Location - 25 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 6336 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/1 Component ID: 397 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 EXHAUST PRESSURE SENSOR SIGNAL K355 18BR/DG Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 6339 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 6340 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/2 Component ID: 398 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 6341 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 6342 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Description Circuit 1 APPS NO. 2 RETURN K400 18BR/VT 2 EXHAUST PRESSURE 1/2 SENSOR SIGNAL K182 18BR/WT 3 5 VOLT SUPPLY K854 18VT/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 6343 Component Location - 25 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 6344 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation DESCRIPTION The fuel tank module is installed in the top of the fuel tank. The fuel tank module contains the following components: - An electric fuel transfer (lift) pump - Fuel reservoir - A separate in-tank fuel filter - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection - A special lockring to retain module to fuel tank - Fuel return line connection. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Removal Fuel Level Sensor: Service and Repair Removal REMOVAL 1. Drain and remove fuel tank. 2. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose. 3. Position Special Tool 9340 (3) into notches on outside edge of lockring (5). 4. Install 1/2 inch drive breaker bar (1) to tool 9340 (3). 5. Rotate breaker bar counterclockwise to remove lockring. 6. Remove lockring. The module will spring up slightly when lockring is removed. 7. Remove module from fuel tank. Be careful not to bend float arm while removing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Removal > Page 6350 Fuel Level Sensor: Service and Repair Installation INSTALLATION CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced. 1. Using a new seal (gasket), position fuel pump module into opening in fuel tank. 2. Position lockring (5) over top of fuel pump module. 3. Rotate module until embossed alignment arrow points to center alignment mark. This step must be performed to prevent float from contacting side of fuel tank. Also be sure fuel fitting on top of pump module is pointed to drivers side of vehicle. 4. Install Special Tool 9340 (3) to lockring. 5. Install 1/2 inch drive breaker (1) into Special Tool 9340 (3). 6. Tighten lockring (clockwise) until all seven notches have engaged. 7. Install fuel tank. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > High Idle Switch > Component Information > Locations High Idle Switch: Locations Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 6354 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 6355 High Idle Switch: Diagrams Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 6356 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations Intake Air Temperature Sensor: Component Locations Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 6361 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 6362 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 6363 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 6364 Component Location - 4 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 6365 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 6366 Cab/Chassis Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. Pick Up Models Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 6367 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 6368 Intake Air Temperature Sensor: Connector Locations Component ID: 406 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (6.7L DH) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 6369 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 6370 Component Location - 7 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 6371 Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 IAT SIGNAL K21 20DB/LG 2 SENSOR GROUND K900 20DB/DG Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 6372 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 6373 Component Location - 7 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 6374 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor Intake Air Temperature Sensor: Diagrams Intake Air Temperature Sensor Component ID: 406 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (6.7L DH) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 6377 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 6378 Component Location - 7 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 6379 Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 IAT SIGNAL K21 20DB/LG 2 SENSOR GROUND K900 20DB/DG Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 6380 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 6381 Component Location - 7 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 6382 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 6383 Intake Air Temperature Sensor: Diagrams Sensor-Temperature/Pressure-MAP Component ID: 427 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A SENSOR GROUND K210 18DB/TN B INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG C 5 VOLT SUPPLY F855 18PK/YL D BOOST PRESSURE SENSOR SIGNAL K37 18LB Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 6384 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 BOOST PRESSURE SENSOR SIGNAL K37 18BR 2 5 VOLT SUPPLY F855 18PK/YL 3 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 3 CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR K735 18BR/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 6385 4 SENSOR GROUND K916 18BR/OR Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 6386 Intake Air Temperature Sensor: Diagrams Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 6387 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 6388 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 6389 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 6390 Component Location - 4 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 6391 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 6392 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Sensor-Temperature/Pressure-Intake Intake Air Temperature Sensor: Description and Operation Sensor-Temperature/Pressure-Intake OPERATION The Inlet Air Temperature/Pressure Sensor is a combination dual-function sensor. The sensor element extends into the intake air stream at the top of the air filter housing. Ambient air temperature as well as barometric pressure is monitored by this sensor. The Engine Control Module (ECM) monitors signals from this sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Sensor-Temperature/Pressure-Intake > Page 6395 Intake Air Temperature Sensor: Description and Operation Sensor-Temperature/Pressure-MAP OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet Intake Air Temperature Sensor: Service and Repair Sensor-Temperature/Pressure-Inlet Removal REMOVAL The Inlet Air Temperature/Pressure Sensor (3) is located on the air cleaner cover. 1. Disconnect electrical connector (7) at sensor. 2. Remove mounting screw (2). 3. Remove sensor from air cleaner cover. 4. Check condition of sensor O-ring. Installation INSTALLATION 1. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 6398 2. Position sensor (3) into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (2). 4. Install electrical connector (7). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 6399 Intake Air Temperature Sensor: Service and Repair Sensor-Temperature/Pressure-MAP Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Pick Up Models REMOVAL-PICK UP MODELS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 6400 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-Inlet > Page 6401 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Description Knock Sensor: Description and Operation Description DESCRIPTION Two knock sensors are bolted into the cylinder block under the intake manifold 3.7L, 4.7L & 8.3L. Two knock sensors are also used with the 5.7L. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Description > Page 6406 Knock Sensor: Description and Operation Operation OPERATION Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure Manifold Pressure/Vacuum Sensor: Locations Sensor-Manifold Absolute Pressure Component ID: 411 Component : SENSOR-MANIFOLD ABSOLUTE PRESSURE Connector: Name : SENSOR-MANIFOLD ABSOLUTE PRESSURE Color : GRAY # of pins : 3 Qualifier : (NGC) Pin Description Circuit 1 MAP SIGNAL K1 20VT/BR 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 6411 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 6412 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 6413 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 6414 Manifold Pressure/Vacuum Sensor: Locations Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 6415 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 6416 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 6417 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 6418 Component Location - 4 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 6419 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 6420 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Manifold Absolute Pressure > Page 6421 Manifold Pressure/Vacuum Sensor: Locations Sensor-Temperature/Pressure-MAP Pick Up Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). Cab/Chassis Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Manifold Absolute Pressure Component ID: 411 Component : SENSOR-MANIFOLD ABSOLUTE PRESSURE Connector: Name : SENSOR-MANIFOLD ABSOLUTE PRESSURE Color : GRAY # of pins : 3 Qualifier : (NGC) Pin Description Circuit 1 MAP SIGNAL K1 20VT/BR 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 6424 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 6425 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 6426 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 6427 Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Temperature/Pressure-Inlet Component ID: 426 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 SENSOR GROUND K690 18BR/YL 2 INLET AIR TEMPERATURE SENSE K615 18VT/WT 3 5 VOLT SUPPLY K668 18BR 4 INLET AIR PRESSURE SENSE K616 18BR/YL Component Location - 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 6428 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 6429 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 6430 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 INLET AIR PRESSURE SENSE K616 18BR/YL 2 5 VOLT SUPPLY F855 18PK/YL 3 INLET AIR TEMPERATURE SENSE K615 18VT/WT 4 SENSOR GROUND K916 18BR/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 6431 Component Location - 4 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 6432 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 6433 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 6434 Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Temperature/Pressure-MAP Component ID: 427 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A SENSOR GROUND K210 18DB/TN B INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG C 5 VOLT SUPPLY F855 18PK/YL D BOOST PRESSURE SENSOR SIGNAL K37 18LB Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 6435 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 BOOST PRESSURE SENSOR SIGNAL K37 18BR 2 5 VOLT SUPPLY F855 18PK/YL 3 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18DB/LG 3 CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR K735 18BR/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Manifold Absolute Pressure > Page 6436 4 SENSOR GROUND K916 18BR/OR Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Sensor-MAP Manifold Pressure/Vacuum Sensor: Description and Operation Sensor-MAP DESCRIPTION A combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is used. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Sensor-MAP > Page 6439 Manifold Pressure/Vacuum Sensor: Description and Operation Sensor-Temperature/Pressure-MAP OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Removal-Pick Up Models REMOVAL-PICK UP MODELS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 6442 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 6443 Manifold Pressure/Vacuum Sensor: Service and Repair Installation Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 6444 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6449 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6450 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6451 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6452 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6453 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6454 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6455 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6456 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6457 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6458 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6459 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6460 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6461 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6462 Oil Pressure Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6463 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6464 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6465 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6466 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 6475 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 6476 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 6477 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 6478 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 6479 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 6480 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 6481 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 6487 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 6488 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 6489 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 08-035-08 > Nov > 08 > Engine Controls - Oxygen Sensor Testing Information Oxygen Sensor: All Technical Service Bulletins Engine Controls - Oxygen Sensor Testing Information NUMBER: 08-035-08 GROUP: Electrical DATE: November 21, 2008 SUBJECT: Proper Testing Tools For Oxygen Sensor Terminals OVERVIEW: This bulletin describes the use of proper test probes to test the Oxygen (02) Sensor connector terminals equipped with the new TP2 style of sensor. MODELS: 2007-2009 (DH) 2500 Pick Up 2007-2009 (D1) 3500 Pick Up NOTE: This bulletin applies to models equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: The new TP2 style 02 sensors have smaller terminals that may be damaged (spread) when using standard Digital Volt Ohm Meter (DVOM) test probes. The recommended tool for these testing procedures is the Miller Tool # 6801 (Fig. 1) Two (2) of these probes are required when performing circuit tests as described in DealerCONNECT. The tool was originally included as part of Miller Tool # 6807 and # 8197A. Each of these kits contained one (1) # 6801 terminal probe. Two (2) additional Miller test probes # 6801 will be delivered to affected Dodge dealers shortly. Two (2) new terminal probes (# 6801) will be included and shipped as kit # 10190. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 6499 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 6500 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 6501 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 6506 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 6507 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 6508 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 6509 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 6510 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 6511 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 6512 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 08-035-08 > Nov > 08 > Engine Controls - Oxygen Sensor Testing Information Oxygen Sensor: All Technical Service Bulletins Engine Controls - Oxygen Sensor Testing Information NUMBER: 08-035-08 GROUP: Electrical DATE: November 21, 2008 SUBJECT: Proper Testing Tools For Oxygen Sensor Terminals OVERVIEW: This bulletin describes the use of proper test probes to test the Oxygen (02) Sensor connector terminals equipped with the new TP2 style of sensor. MODELS: 2007-2009 (DH) 2500 Pick Up 2007-2009 (D1) 3500 Pick Up NOTE: This bulletin applies to models equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: The new TP2 style 02 sensors have smaller terminals that may be damaged (spread) when using standard Digital Volt Ohm Meter (DVOM) test probes. The recommended tool for these testing procedures is the Miller Tool # 6801 (Fig. 1) Two (2) of these probes are required when performing circuit tests as described in DealerCONNECT. The tool was originally included as part of Miller Tool # 6807 and # 8197A. Each of these kits contained one (1) # 6801 terminal probe. Two (2) additional Miller test probes # 6801 will be delivered to affected Dodge dealers shortly. Two (2) new terminal probes (# 6801) will be included and shipped as kit # 10190. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 6522 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 6523 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 6524 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 6534 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 6535 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 6536 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 6537 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 6538 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 6539 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 6540 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen Oxygen Sensor: Locations Sensor - Oxygen The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6543 Oxygen Sensor: Locations Sensor - Oxygen 1/1 Component ID: 416 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : BLACK # of pins : 4 Qualifier : (3.7L/5.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6544 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6545 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6546 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6547 Connector: Name : SENSOR-OXYGEN 1/1 Color : GRAY # of pins : 4 Qualifier : (4.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6548 Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6549 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6550 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6551 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6552 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6553 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6554 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6555 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6556 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6557 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6558 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6559 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6560 Oxygen Sensor: Locations Sensor - Oxygen 1/2 Component ID: 417 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 4 Qualifier : (3.7L/5.7L LD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6561 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6562 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6563 Connector: Name : SENSOR-OXYGEN 1/2 Color : GRAY # of pins : 4 Qualifier : (4.7L/5.7L HD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6564 Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6565 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6566 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6567 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6568 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6569 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6570 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6571 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen > Page 6572 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor Oxygen Sensor: Diagrams Module-O2 Sensor Component ID: 207 Component : MODULE-O2 SENSOR Connector: Name : MODULE-O2 SENSOR Color : # of pins : 16 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 3 DIAGNOSTIC PORT LOW DATA LINK D132 20WT 4 O2 1/2 SIGNAL K141 20DB/YL 5 02 1/2 PUMP CURRENT K734 20BR/DG 6 O2 1/1 SIGNAL K41 20DB/LB 7 02 1/1 PUMP CURRENT K89 20BR/LG 8 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 9 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 10 GROUND Z902 20BK 11 DIAGNOSTIC PORT HIGH DATA LINK D133 20WT/OR 12 O2 1/2 RETURN K904 20DB/DG 13 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 14 O2 1/1 RETURN K902 20BR/DG 15 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 16 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB Connector: Name : MODULE-O2 SENSOR Color : # of pins : 16 Qualifier : (6.7L DIESEL) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6575 Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 3 DIAGNOSTIC PORT LOW DATA LINK D132 20WT 4 O2 1/2 SIGNAL K141 20DB/YL 5 02 1/2 PUMP CURRENT K734 20BR/DG 6 O2 1/1 SIGNAL K41 20DB/LB 7 02 1/1 PUMP CURRENT K89 20BR/LG 8 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 9 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 10 GROUND Z902 20BK 11 DIAGNOSTIC PORT HIGH DATA LINK D133 20WT/OR 12 O2 1/2 RETURN K904 20DB/DG 13 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 14 O2 1/1 RETURN K902 20BR/DG 15 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 16 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6576 Oxygen Sensor: Diagrams Sensor-Oxygen 1/1 Component ID: 416 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : BLACK # of pins : 4 Qualifier : (3.7L/5.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6577 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6578 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6579 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6580 Connector: Name : SENSOR-OXYGEN 1/1 Color : GRAY # of pins : 4 Qualifier : (4.7L) Pin Description Circuit 1 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG 2 GROUND Z42 20BK/LG 3 O2 1/1 RETURN K902 20BR/DG 4 O2 1/1 SIGNAL K41 20DB/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6581 Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6582 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6583 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6584 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6585 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6586 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6587 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6588 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/1 PUMP CURRENT K89 20BR/LG 2 O2 1/1 RETURN K902 20BR/DG 3 O2 1/1 HEATER CONTROL RETURN K79 20BR/LB 4 O2 1/1 HEATER CONTROL SUPPLY K99 20BR/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6589 5 O2 1/1 PUMP CELL CURRENT TRIM K103 20BR/LB 6 O2 1/1 SIGNAL K41 20DB/LB Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6590 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6591 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6592 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6593 Oxygen Sensor: Diagrams Sensor-Oxygen 1/2 Component ID: 417 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 4 Qualifier : (3.7L/5.7L LD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6594 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6595 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6596 Connector: Name : SENSOR-OXYGEN 1/2 Color : GRAY # of pins : 4 Qualifier : (4.7L/5.7L HD) Pin Description Circuit 1 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT 2 GROUND Z43 20BK/LB 3 O2 1/2 RETURN K904 20DB/DG 4 O2 1/2 SIGNAL K141 20DB/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6597 Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6598 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6599 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6600 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6601 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6602 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 02 1/2 PUMP CURRENT K734 20BR/DG 2 O2 1/2 RETURN K904 20DB/DG 3 O2 1/2 HEATER CONTROL RETURN K80 20BR/TN 4 O2 1/2 HEATER CONTROL SUPPLY K299 20BR/WT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6603 5 O2 1/2 PUMP CELL CURRENT TRIM K733 20BR 6 O2 1/2 SIGNAL K141 20DB/YL Component Location - 21 Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6604 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 6605 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description Pick Up Models Oxygen Sensor: Description and Operation Description - Pick Up Models DESCRIPTION - PICK UP MODELS The two oxygen (O2) sensors (1) and (2) are located at each end of the #2 catalyst. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description Pick Up Models > Page 6608 Oxygen Sensor: Description and Operation Operation - Pick Up Models OPERATION - PICK UP MODELS Two different six-wire O2 sensors are used. These sensors are titled 1/1 upstream (1), and 1/2 downstream (2). A separate O2 Sensor Module (1) is also used. The engine aftertreatment system monitors the O2 content in the diesel engine exhaust. The ECM monitors the exhaust gases for oxygen content and varies the rich/lean fuel mixture of the intake air fuel mixture to adjust the system. This diagnostic monitors the status message broadcast by the O2 Sensor Module (1) for the upstream O2 sensor's internal heater circuit. The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the O2 Sensor Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description Pick Up Models > Page 6609 Oxygen Sensor: Description and Operation Oxygen Sensor Module Description - Pick Up Models DESCRIPTION - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). Operation - Pick Up Models OPERATION - PICK UP MODELS Two different six-wire O2 sensors are used. These sensors are titled 1/1 upstream, and 1/2 downstream. A separate O2 Sensor Module (1) is also used. The engine aftertreatment system monitors the O2 content in the diesel engine exhaust. The ECM monitors the exhaust gases for oxygen content and varies the rich/lean fuel mixture of the intake air fuel mixture to adjust the system. This diagnostic monitors the status message broadcast by the O2 Sensor Module (1) for the upstream O2 sensor's internal heater circuit. The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the O2 Sensor Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module Oxygen Sensor: Service and Repair Oxygen Sensor Module Removal - Pick Up Models REMOVAL - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). 1. Raise and support vehicle. 2. Disconnect electrical connector (2) at module (1). 3. Remove four bolts (3). 4. Remove module from frame rail. Installation - Pick Up Models INSTALLATION - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). 1. Position module (1) to frame rail (4). 2. Install four bolts (3). 3. Tighten bolts (3) to 6 Nm (53 in. lbs.) torque. 4. Connect electrical connector (2) to module (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 6612 5. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 6613 Oxygen Sensor: Service and Repair Removal REMOVAL - PICK UP MODELS The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: The exhaust manifold, exhaust pipes and catalytic converters become very hot during engine operation. Allow engine to cool before removing oxygen sensor. 1. Raise and support vehicle. 2. Disconnect main wire connector from O2S sensor pigtail harness. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove O2S sensor with an oxygen sensor removal and installation tool. 4. Clean threads in catalytic convertor using appropriate tap. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 6614 Oxygen Sensor: Service and Repair Installation INSTALLATION - PICK UP MODELS The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. Threads of NEW oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. Be careful not to get anti-seize compound on sensor tip. 1. Install O2S sensor. Tighten to 41 Nm (30 ft. lbs.) torque. 2. Connect O2S sensor pigtail harness to main wire harness connector. 3. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Description Power Steering Pressure Switch: Description and Operation Description DESCRIPTION A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will only be used on HD vehicles with the 5.7L engines. There is no pressure switch used for the 3.7L, 4.7L, 5.9LDiesel engine or the 5.7L LD vehicle pump. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Description > Page 6619 Power Steering Pressure Switch: Description and Operation Operation OPERATION The switch is used on the 5.7L V-8 engines HD vehicles only. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal Pressure Feedback Exhaust Sensor: Service and Repair Removal REMOVAL 1. Disconnect exhaust gas pressure sensor electrical connector (1). 2. Using a 6 point deepwell socket, remove exhaust gas sensor (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal > Page 6624 Pressure Feedback Exhaust Sensor: Service and Repair Installation INSTALLATION 1. Using a 6 point deepwell socket, install exhaust gas pressure sensor. 2. Tighten sensor to 18 Nm (13 ft. lbs.). 3. Connect exhaust gas pressure sensor electrical connector (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6629 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6630 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6631 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6632 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6633 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6634 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6635 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6636 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6637 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6638 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6639 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6642 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6643 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6644 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6645 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6646 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6647 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6648 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6649 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6650 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6651 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6652 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 6655 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 6656 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 6657 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 6658 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 6659 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 6662 TRS REMOVAL/INSTALLATION 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 6663 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 6664 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 6665 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 6666 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations Turbocharger Speed Sensor: Locations Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations > Page 6670 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations > Page 6671 Turbocharger Speed Sensor: Diagrams Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations > Page 6672 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6677 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6678 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6679 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6680 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6681 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6682 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6683 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6684 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6685 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6686 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6687 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6688 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6689 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6690 Vehicle Speed Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6691 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6692 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6693 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6694 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6699 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6700 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6701 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6702 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6703 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6704 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6705 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6706 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6707 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6708 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 6709 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6712 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6713 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6714 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6715 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6716 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6717 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6718 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6719 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6720 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6721 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 6722 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 6725 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 6726 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 6727 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 6728 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 6729 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 6732 TRS REMOVAL/INSTALLATION 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 6733 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 6734 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 6735 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 6736 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations Turbocharger Speed Sensor: Locations Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations > Page 6740 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations > Page 6741 Turbocharger Speed Sensor: Diagrams Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Turbocharger Speed Sensor > Component Information > Locations > Page 6742 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6747 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6748 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6749 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6750 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6751 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6752 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6753 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6754 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6755 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6756 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6757 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6758 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6759 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6760 Vehicle Speed Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6761 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6762 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6763 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 6764 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6771 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6772 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6773 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6774 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6775 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6776 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6777 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6778 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6781 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6782 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6783 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6784 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6785 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6786 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6787 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6788 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 6791 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 6794 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Description and Operation Exhaust Pressure Differential Sensor: Description and Operation DESCRIPTION The Exhaust Differential Pressure Sensor is remotely mounted on the transmission housing. Two pressure tubes measure pressure before and after the Diesel Particulate Filter (DPF)/Diesel Oxidation Catalyst (DOC). The sensor is critical for fail-safe of regeneration strategy, because it interprets high pressure drops as possible high soot loads. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Differential Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect electrical connector. 3. Disconnect hoses at pressure differential pressure sensor. 4. Remove mounting bolt and differential pressure sensor. 5. Remove mounting bolts (1). 6. Remove pressure differential pressure tubing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal > Page 6801 Exhaust Pressure Differential Sensor: Service and Repair Installation INSTALLATION 1. Install differential pressure tubing, if removed. Tighten fittings to 30 Nm (22 ft. lbs.). 2. Position differential pressure sensor (1). 3. Install mounting nuts (5) and bolts. Tighten to 10 Nm (89 in. lbs.). 4. Install hose (2) to the rear DPF tubing. 5. Install hose (3) to the front DPF tubing. 6. Connect electrical connector (6). 7. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > Customer Interest for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F Diesel Particle Filter (DPF): Customer Interest Engine Controls - MIL ON/DTC's P1451/P200C/P242F NUMBER: 11-001-09 GROUP: Exhaust DATE: July 23, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-002-07, DATED SEPTEMBER 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED TOOL FOR THIS PROCEDURE. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE STANDALONE MODE OR StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Diesel Particulate Filter - Diagnosis and Repair of DTC's P1451, P200C, P242F or Black Smoke From Exhaust OVERVIEW: This bulletin provides revised diagnostic and repair procedures for DTC's P1451, P2OOC, P242F, black smoke from the exhaust, or a no start condition due to a nonfunctional or plugged Diesel Particulate Filter (DPF). The Mobile DeSoot procedure initiated by the service tool will soon be replaced with a new Stationary DeSoot procedure. The stationary DeSoot procedure will only work when a vehicle needs to have a DeSoot performed, such as is indicated by the presence of an active P1451. A Service Bulletin will be released when this procedure becomes available. MODELS: 2007 - 2009 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination, warning chime and an overhead Electronic Vehicle Information Center (EVIC) message regarding the aftertreatment system and/or black smoke from the exhaust and/or a no start condition. Further Investigation by the technician may reveal that the MIL illumination and/or EVIC message is due to one or more of the following Diagnostic Trouble Codes (DTC's): ^ P1451 - Diesel Particulate Filter - System Performance. ^ P242F - Diesel Particulate Filter Restriction - Ash Accumulation. ^ P200C - Diesel Particulate Filter Over Temperature - Bank 1. NOTE: While the wiTECH tool is the preferred method of testing, StarMOBILE desktop client, StarMOBILE standalone mode OR StarSCAN may also be used to perform this procedure. DIAGNOSIS: 1. Connect the Scan Tool to the Diagnostic Link Connector (DLC). 2. Turn the ignition key to the RUN position, DO NOT start the engine. 3. From the "Vehicle View" screen on the Scan Tool select: a. "All DTCs" tab. 4. Record all Diagnostic Trouble Codes (DTC's) that are present in the PCM. NOTE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > Customer Interest for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F > Page 6810 It is IMPORTANT to record (capture) all DTC's present in the PCM prior to proceeding further with this diagnosis. 5. Are DTC's P242F and/or P200C present, either active or stored, in the PCM, or does the vehicle have visible black smoke from the exhaust or a no start condition caused by a restricted exhaust? a. If YES >> then the Diesel Particulate Filter (DPF) may require replacement. Proceed to REPAIR PROCEDURE B: DPF Repair Procedure. b. If NO >> then proceed to Step # 6. 6. Is DTC P1451 ACTIVE in the PCM (but DTC's P242F and/or P200C are NOT present and there is no black smoke concern)? a. If YES >> then a Scan Tool initiated DeSoot is required for the DPF. Proceed to REPAIR PROCEDURE A: DPF DeSoot. b. If NO >> then STOP. Additional diagnosis or repair for the DPF is not needed. An inactive DTC P1451 without other symptoms does not require any repair. Confirm that the PCM has the latest updates per the relevant TSB's and include the documentation kit p/n 6804917AA (while supplies last) in the vehicle, and resolve any other concerns prior to returning the vehicle to the owner. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURES: NOTE: Detailed removal and installation procedures (and graphics), required to perform this bulletin, will not be listed individually in each Inspection and Test Section of this Repair Procedure. It will be important to refer to TechCONNECT for all detailed service procedures. REPAIR PROCEDURE A: DPF DeSoot 1. Resolve all DTC's unrelated to DeSoot. NOTE: DeSoot only addresses the amount of particulate matter (soot) in the DPF, such as indicated by an active P1451. It DOES NOT address any other issues or conditions. 2. Confirm the PCM Calibration software is at the latest revision level. If an update is required, follow the latest calibration update TSB. WARNING: Elevated exhaust temperatures during Scan Tool initiated DeSoot can cause personal injury or property damage. It is important that ALL procedures are followed. 3. Refer to TSB or Service Information available in DealerCONNECT for information to perform a Scan Tool initiated DeSoot. REPAIR PROCEDURE B: DPF Repair Procedure NOTE: The DPF repair procedure has been updated due to diagnostic and controls enhancements. 1. Does the vehicle have a no start condition WITHOUT P242F in the PCM? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > Customer Interest for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F > Page 6811 a. If YES »> then proceed to Step # 2. b. If NO »> then proceed to Step # 3. 2. Disconnect the DPF from the NOx Absorber Catalyst (NAG) by removing the three nuts at the flange between them. Insert a non-flammable spacer between the NAG and DPF flanges to create an exhaust leak path. Does this resolve the no start condition? a. Yes >> proceed to Step # 3. b. No >> then STOP. The no start condition is NOT caused by the DPF. DPF replacement is NOT needed, and this bulletin DOES NOT apply. 3. Replace the DPF. Refer to the detailed removal and installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 11 - Exhaust Systems > Converter, Catalytic > Removal/Installation > 6.7L diesel P/U. 4. Clean the EGR valve. Refer to the detailed cleaning procedures available in DealerCONNECT > TechCONNECT under: 25 - Emissions Controls > Exhaust Gas Recirculation, 6.7L Diesel > Valve, Exhaust Gas Recirculation (EGR), 6.7L > Cleaning. 5. Ensure all other engine driveability symptom and/or aftertreatment-related DTC's are addressed. 6. Confirm the PCM application software is at the latest revision level. If an update is required, follow the latest calibration update TSB. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Use Standard Labor Operation Times FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F Diesel Particle Filter (DPF): All Technical Service Bulletins Engine Controls - MIL ON/DTC's P1451/P200C/P242F NUMBER: 11-001-09 GROUP: Exhaust DATE: July 23, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-002-07, DATED SEPTEMBER 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED TOOL FOR THIS PROCEDURE. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE STANDALONE MODE OR StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Diesel Particulate Filter - Diagnosis and Repair of DTC's P1451, P200C, P242F or Black Smoke From Exhaust OVERVIEW: This bulletin provides revised diagnostic and repair procedures for DTC's P1451, P2OOC, P242F, black smoke from the exhaust, or a no start condition due to a nonfunctional or plugged Diesel Particulate Filter (DPF). The Mobile DeSoot procedure initiated by the service tool will soon be replaced with a new Stationary DeSoot procedure. The stationary DeSoot procedure will only work when a vehicle needs to have a DeSoot performed, such as is indicated by the presence of an active P1451. A Service Bulletin will be released when this procedure becomes available. MODELS: 2007 - 2009 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination, warning chime and an overhead Electronic Vehicle Information Center (EVIC) message regarding the aftertreatment system and/or black smoke from the exhaust and/or a no start condition. Further Investigation by the technician may reveal that the MIL illumination and/or EVIC message is due to one or more of the following Diagnostic Trouble Codes (DTC's): ^ P1451 - Diesel Particulate Filter - System Performance. ^ P242F - Diesel Particulate Filter Restriction - Ash Accumulation. ^ P200C - Diesel Particulate Filter Over Temperature - Bank 1. NOTE: While the wiTECH tool is the preferred method of testing, StarMOBILE desktop client, StarMOBILE standalone mode OR StarSCAN may also be used to perform this procedure. DIAGNOSIS: 1. Connect the Scan Tool to the Diagnostic Link Connector (DLC). 2. Turn the ignition key to the RUN position, DO NOT start the engine. 3. From the "Vehicle View" screen on the Scan Tool select: a. "All DTCs" tab. 4. Record all Diagnostic Trouble Codes (DTC's) that are present in the PCM. NOTE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F > Page 6817 It is IMPORTANT to record (capture) all DTC's present in the PCM prior to proceeding further with this diagnosis. 5. Are DTC's P242F and/or P200C present, either active or stored, in the PCM, or does the vehicle have visible black smoke from the exhaust or a no start condition caused by a restricted exhaust? a. If YES >> then the Diesel Particulate Filter (DPF) may require replacement. Proceed to REPAIR PROCEDURE B: DPF Repair Procedure. b. If NO >> then proceed to Step # 6. 6. Is DTC P1451 ACTIVE in the PCM (but DTC's P242F and/or P200C are NOT present and there is no black smoke concern)? a. If YES >> then a Scan Tool initiated DeSoot is required for the DPF. Proceed to REPAIR PROCEDURE A: DPF DeSoot. b. If NO >> then STOP. Additional diagnosis or repair for the DPF is not needed. An inactive DTC P1451 without other symptoms does not require any repair. Confirm that the PCM has the latest updates per the relevant TSB's and include the documentation kit p/n 6804917AA (while supplies last) in the vehicle, and resolve any other concerns prior to returning the vehicle to the owner. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURES: NOTE: Detailed removal and installation procedures (and graphics), required to perform this bulletin, will not be listed individually in each Inspection and Test Section of this Repair Procedure. It will be important to refer to TechCONNECT for all detailed service procedures. REPAIR PROCEDURE A: DPF DeSoot 1. Resolve all DTC's unrelated to DeSoot. NOTE: DeSoot only addresses the amount of particulate matter (soot) in the DPF, such as indicated by an active P1451. It DOES NOT address any other issues or conditions. 2. Confirm the PCM Calibration software is at the latest revision level. If an update is required, follow the latest calibration update TSB. WARNING: Elevated exhaust temperatures during Scan Tool initiated DeSoot can cause personal injury or property damage. It is important that ALL procedures are followed. 3. Refer to TSB or Service Information available in DealerCONNECT for information to perform a Scan Tool initiated DeSoot. REPAIR PROCEDURE B: DPF Repair Procedure NOTE: The DPF repair procedure has been updated due to diagnostic and controls enhancements. 1. Does the vehicle have a no start condition WITHOUT P242F in the PCM? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F > Page 6818 a. If YES »> then proceed to Step # 2. b. If NO »> then proceed to Step # 3. 2. Disconnect the DPF from the NOx Absorber Catalyst (NAG) by removing the three nuts at the flange between them. Insert a non-flammable spacer between the NAG and DPF flanges to create an exhaust leak path. Does this resolve the no start condition? a. Yes >> proceed to Step # 3. b. No >> then STOP. The no start condition is NOT caused by the DPF. DPF replacement is NOT needed, and this bulletin DOES NOT apply. 3. Replace the DPF. Refer to the detailed removal and installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 11 - Exhaust Systems > Converter, Catalytic > Removal/Installation > 6.7L diesel P/U. 4. Clean the EGR valve. Refer to the detailed cleaning procedures available in DealerCONNECT > TechCONNECT under: 25 - Emissions Controls > Exhaust Gas Recirculation, 6.7L Diesel > Valve, Exhaust Gas Recirculation (EGR), 6.7L > Cleaning. 5. Ensure all other engine driveability symptom and/or aftertreatment-related DTC's are addressed. 6. Confirm the PCM application software is at the latest revision level. If an update is required, follow the latest calibration update TSB. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Use Standard Labor Operation Times FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Description and Operation > Description Diesel Particle Filter (DPF): Description and Operation Description DESCRIPTION DIESEL OXIDATION CATALYST (DOC) The diesel oxidation catalyst (DOC) is a ceramic flow through substrate coated with a catalyst washcoat that is integral to the DOC/Diesel Particulate Filter (DPF) assembly. The close coupled DOC treats engine exhaust gases by converting harmful carbon monoxide, unburned hydrocarbons and other compounds into water, carbon dioxide and heat. DIESEL PARTICULATE FILTER The diesel particulate filter (DPF) is a wall-pass ceramic filter substrate coated with a catalyst washcoat that is integral to the DOC/DPF assembly. The partially treated exhaust gases from the DOC, flow into the catalyzed diesel particulate filter (DPF) which traps and accumulates particulate matter and further treats the exhaust gases to reduce unburned hydrocarbons and other harmful compounds. the trapped particulate molecules will be periodically removed from the DPF via a thermal regeneration process initiated by the engine's electronic control module (ECM). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Description and Operation > Description > Page 6821 Diesel Particle Filter (DPF): Description and Operation Operation OPERATION The oxidation catalyst raises the exhaust gas temperatures to regenerate the DPF, which is passive regeneration. If the passive regeneration cannot keep up with the build up of soot in the DPF, the ECM will actively regenerate the DPF to burn off the soot. Residue remains inside the DPF in the form of non burnable ash. Ash comes from the oils and other materials that are trapped in the oils and are present in the soot. The catalyst contains a large number of parallel channels, which run in the axial direction and are separated by thin porous walls. The channels are alternatively open at one end, but plugged at the other. The exhaust gases flow through the walls and escape through the pores in the wall material. Particulates, however, are too large to escape and are trapped in the monolith walls. The ECM starts the regeneration of the DPF if the soot load exceeds a performance map value. The ECM determines the load condition of the DPF based upon the exhaust gas pressure upstream and downstream of the DPC/DPF. A pressure differential sensor provides the pressure input to the ECM. During the regeneration process, the ECM raises the temperature in the DOC/DPF to burn off the soot accumulated. Under normal operation, the engine does not produce enough heat to oxidize the soot inside the DOC/DPF. This process requires temperatures above 550°C (1,022°F). After regeneration, the ECM reads the actual pressure difference at the DOC/DPF and compares it with a reference value. From this comparison, the ECM determines the ash quantity inside the DOC/DPF. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Description and Operation > Page 6822 Diesel Particle Filter (DPF): Testing and Inspection DIAGNOSIS AND TESTING - DIESEL PARTICULATE FILTER EVIC Message Center - Message - Catalyst Full The engine Electronic Control Module (ECM) monitors the soot load in the diesel particulate filter. Under normal operating conditions the diesel particulate filter is self-cleaning, where accumulated soot is converted to ash. Under light load operating conditions, the driver may be notified via the vehicle's Electronic Vehicle Information Center (EVIC) message center "CATALYST FULL: SEE OWNERS MAN" message will be displayed indicating that it is necessary to modify the vehicles driving routine/duty-cycle in order to allow the diesel particulate filter system to self clean. If the vehicle's EVIC message center notification is ignored, the vehicle will eventually derate the engine and set a fault, requiring service. The soot load in the diesel particulate filter is estimated by the ECM using the Exhaust Pressure Sensor values and the calculated soot output of the engine. This fault code will be triggered if the application is not operating at a duty cycle high enough to allow active regeneration of the diesel particulate filter. This fault code is an indication that the exhaust temperatures exiting the turbocharger are not high enough to allow active regeneration of the soot that is trapped in the diesel particulate filter. It may be necessary to increase the duty cycle of the application in order to prevent excessive soot accumulation and plugging of the diesel particulate filter. The ECM will set this fault if it detects that the soot level has exceeded the normal desoot trigger threshold by a sufficient amount to indicate that the driver intervention is required. There is not a MIL lamp associated with this fault code, though the driver will be notified via the EVIC message. Have owner drive vehicle at highway speeds (50/60 mph) for a minimum of 45 minutes. If the message CATALYST FULL SERVICE REQ'D. is still displayed, Refer to - ENGINE Testing. See: Engine, Cooling and Exhaust/Engine/Testing and Inspection/Component Tests and General Diagnostics Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Removal - Cab Chassis Diesel Particle Filter (DPF): Service and Repair Removal - Cab Chassis 6.7L DIESEL - CAB-CHASSIS WARNING: If torches are used when working on the exhaust system, do not allow the flame near the fuel lines. 1. Raise and support the vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Remove flexible tubing from particulate filter pressure sensor tubing. 4. Loosen and remove particulate filter pressure sensor tubing from Diesel Oxidation Catalytic/Diesel Particulate Filter (DOC/DPF). 5. Disconnect and remove temperature sensors. 6. 4X4 Vehicles Remove transfer case skid plate. 7. 4X4 Vehicles - Remove transmission crossmember. 8. Remove exhaust pipe to DOC/DPF flange nuts (5) 9. Remove intermediate pipe to DOC/PDF clamp nuts (2). 10. Move muffler and tail pipe assembly (1) toward rear of vehicle. 11. Remove DOC/DPF (4). 12. Remove and discard flange gaskets. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Removal - Cab Chassis > Page 6825 Diesel Particle Filter (DPF): Service and Repair Removal - P/U 6.7L DIESEL - P/U 1. Raise and support the vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Loosen and remove DPF differential pressure tubes (4 and 6). 4. Disconnect and remove temperature sensor (2). 5. 4X4 Vehicles - Remove transfer case skid plate. 6. 4X4 Vehicles - Remove transmission crossmember. 7. Remove DPF to muffler clamp (5). Discard clamp. 8. Move muffler and tail pipe assembly toward rear of vehicle. 9. Remove DPF to catalytic converter flange nuts. 10. Remove DPF. Discard flange gaskets. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Removal - Cab Chassis > Page 6826 Diesel Particle Filter (DPF): Service and Repair Installation - Cab Chassis 6.7L DIESEL - CAB-CHASSIS 1. Position new exhaust flange gaskets on exhaust pipe (6) to DOC/DPF flange and DOC/DPF into intermediate pipe (1). 2. Using new gasket, position the DOC/DPF (4) onto the front exhaust pipe flange. 3. Install flange nuts (5). Hand tighten only. 4. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 5. Tighten flange nuts (5) to 54 Nm (40 ft. lbs) 6. Tighten torque clamp nuts to 52 Nm (40 ft. lbs.) 7. Install temperature sensor. Tighten to 29.8 Nm (22 ft. lbs.) 8. Install exhaust differential pressure tubing. Tighten to 30 Nm (22 ft. lbs.) 9. Install flexible exhaust differential pressure sensor tubing. 10. 4X4 Vehicles - Install transmission crossmember. 11. 4X4 Vehicles - Install transfer case skid plate. 12. Connect electrical connectors. 13. Connect negative battery cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Removal - Cab Chassis > Page 6827 Diesel Particle Filter (DPF): Service and Repair Installation - P/U 6.7L DIESEL - P/U 1. Position new exhaust flange gaskets on catalytic converter to DPF flange. 2. Install flange bolts. Hand tighten only. 3. Install muffler and tailpipe assembly 4. Install new band clamp. Hand tighten only. 5. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 6. Tighten flange nuts to 54 Nm (40 ft. lbs) 7. Tighten band clamp nuts to 52 Nm (40 ft. lbs.) 8. Install temperature sensor. Tighten to 29.8 Nm (22 ft. lbs.) 9. Install front and rear (6 and 4) exhaust differential pressure tubing. Tighten to 30 Nm (22 ft. lbs.) 10. Install flexible exhaust differential pressure sensor tubing. 11. 4X4 Vehicles - Install transmission crossmember. 12. 4X4 Vehicles - Install transfer case skid plate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Canister Purge Solenoid: Locations Component ID: 441 Component : SOLENOID-EVAP PURGE Connector: Name : SOLENOID-EVAP PURGE Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 EVAP PURGE CONTROL K52 20DB/WT 2 EVAP PURGE SOL SIGNAL K70 20DB/BR Component Location - 32 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 6832 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 6833 Canister Purge Solenoid: Diagrams Component ID: 441 Component : SOLENOID-EVAP PURGE Connector: Name : SOLENOID-EVAP PURGE Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 EVAP PURGE CONTROL K52 20DB/WT 2 EVAP PURGE SOL SIGNAL K70 20DB/BR Component Location - 32 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 6834 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations Leak Detector: Locations Component ID: 464 Component : SWITCH-EVAP SYSTEM MONITOR Connector: Name : SWITCH-EVAP SYSTEM MONITOR Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 GROUND Z910 20BK 2 ESM SIGNAL K107 20VT/WT Component Location - 23 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Page 6838 Component Location - 69 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Page 6839 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Page 6840 Leak Detector: Diagrams Component ID: 464 Component : SWITCH-EVAP SYSTEM MONITOR Connector: Name : SWITCH-EVAP SYSTEM MONITOR Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 GROUND Z910 20BK 2 ESM SIGNAL K107 20VT/WT Component Location - 23 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Page 6841 Component Location - 69 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Page 6842 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > Recalls: > NHTSA08V641000 > Dec > 08 > Recall 08V641000: Potential Engine Compartment Fire EGR Cooler: Recalls Recall 08V641000: Potential Engine Compartment Fire VEHICLE MAKE/MODEL: MODEL YEAR(S): Dodge/RAM 2500 2007-2008 Dodge/RAM 3500 2007-2008 MANUFACTURER: Chrysler LLC. MFR'S REPORT DATE: December 04, 2008 NHTSA CAMPAIGN ID NUMBER: 08V641000 NHTSA ACTION NUMBER: N/A COMPONENT: Engine and Engine Cooling: Engine: Diesel POTENTIAL NUMBER OF UNITS AFFECTED: 108429 SUMMARY: Chrysler is recalling 108,429 M/Y 2007-2008 Dodge RAM 2500 and 3500 pickup trucks equipped with 6.7L Diesel engines. A silencer pad can sag and contact the Exhaust Gas Recirculation (EGR) cooler. CONSEQUENCE: This could result in an engine compartment fire. REMEDY: Dealers will add a bracket to support the engine compartment silencer pad adjacent to the EGR cooler. The recall is expected to begin during December 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H34. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > NHTSA08V641000 > Dec > 08 > Recall 08V641000: Potential Engine Compartment Fire EGR Cooler: All Technical Service Bulletins Recall 08V641000: Potential Engine Compartment Fire VEHICLE MAKE/MODEL: MODEL YEAR(S): Dodge/RAM 2500 2007-2008 Dodge/RAM 3500 2007-2008 MANUFACTURER: Chrysler LLC. MFR'S REPORT DATE: December 04, 2008 NHTSA CAMPAIGN ID NUMBER: 08V641000 NHTSA ACTION NUMBER: N/A COMPONENT: Engine and Engine Cooling: Engine: Diesel POTENTIAL NUMBER OF UNITS AFFECTED: 108429 SUMMARY: Chrysler is recalling 108,429 M/Y 2007-2008 Dodge RAM 2500 and 3500 pickup trucks equipped with 6.7L Diesel engines. A silencer pad can sag and contact the Exhaust Gas Recirculation (EGR) cooler. CONSEQUENCE: This could result in an engine compartment fire. REMEDY: Dealers will add a bracket to support the engine compartment silencer pad adjacent to the EGR cooler. The recall is expected to begin during December 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H34. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > All Other Service Bulletins for EGR Cooler: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set Control Module: All Technical Service Bulletins Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > All Other Service Bulletins for EGR Cooler: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 6862 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > All Other Service Bulletins for EGR Cooler: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 6863 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > All Other Service Bulletins for EGR Cooler: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: All Technical Service Bulletins A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > All Other Service Bulletins for EGR Cooler: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 6868 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > All Other Service Bulletins for EGR Cooler: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 6869 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > All Other Service Bulletins for EGR Cooler: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set Control Module: All Technical Service Bulletins A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > All Other Service Bulletins for EGR Cooler: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 6874 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > All Other Service Bulletins for EGR Cooler: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 6875 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > All Other Service Bulletins for EGR Cooler: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 6876 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > All Other Service Bulletins for EGR Cooler: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 6877 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > All Other Service Bulletins for EGR Cooler: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 6883 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > All Other Service Bulletins for EGR Cooler: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 6884 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > All Other Service Bulletins for EGR Cooler: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 6889 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > All Other Service Bulletins for EGR Cooler: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 6890 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > All Other Service Bulletins for EGR Cooler: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 6895 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > All Other Service Bulletins for EGR Cooler: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 6896 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > All Other Service Bulletins for EGR Cooler: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 6897 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > All Other Service Bulletins for EGR Cooler: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 6898 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > Page 6899 EGR Cooler: Diagrams Component ID: 498 Component : VALVE-EGR COOLER BYPASS Connector: Name : VALVE-EGR COOLER BYPASS Color : # of pins : 4 Qualifier : (6.7L DH/D1) Pin Description Circuit 1 EGR BYPASS STATUS K671 18BR/DB 2 EGR BYPASS VALVE SIGNAL K670 18BR/LB 3 SMART POWER RELAY FEED F348 16PK/OR 4 ACTUATOR GROUND K972 18DB/TN Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Description and Operation > Description EGR Cooler: Description and Operation Description DESCRIPTION The Exhaust Gas Recycling cooler is located above the exhaust manifold on the right side of the engine. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Description and Operation > Description > Page 6902 EGR Cooler: Description and Operation Operation OPERATION Exhaust gas enter the rear portion of the EGR Cooler from the exhaust manifold. The gas is cooled as it passes through the EGR Cooler and then enters the EGR crossover tube and is routed to the EGR valve. Coolant enters the rear of the EGR Cooler and flow the same direction as the exhaust gases. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures EGR Cooler: Procedures CLEANING 1. Remove EGR Cooler. 2. Spray the internal cavity of EGR Cooler with hot tap water for 10 minutes. 3. Plug EGR Cooler outlet (1) with a locally obtained rubber expansion plug to make a watertight seal. 4. Following instruction on the container, mix MOPAR(R) EGR System Cleaner and hot tap water with a ratio of one part EGR Cleaner, four parts water. 5. Position EGR Cooler with the outlet (1) facing up. Fill EGR Cooler with hot tap water and MOPAR(R) EGR System Cleaner until cooler is completely full. Soak for one hour. 6. Remove plug from EGR Cooler outlet (1). Drain cleaning solution from cooler. Discard according to local governmental regulations. 7. Rinse cooler using hot tap water until all cleaning solution has been rinsed clean. Dry completely. 8. Install EGR Cooler. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6905 EGR Cooler: Removal and Replacement Removal REMOVAL EGR COOLER - 6.7L DIESEL - P/U WARNING: Locking constant tension hose clamps are used on the EGR cooler system hoses. When removing, use only tools designed for servicing this type of clamp. Always wear safety glasses when servicing locking constant tension clamps. 1. Remove engine cover. 2. Drain cooling system below level of EGR cooler. 3. Disconnect EGR bypass control electrical connector (1), (if equipped). 4. Remove EGR bypass control assembly (2) and position aside, (if equipped). EGR COOLER - 6.7L DIESEL - CAB-CHASSIS 5. Remove EGR crossover tube clamp (4) and crossover tube (5). 6. Remove EGR Transfer Connection Tube from casting, (if equipped). 7. Using Tool 6094, remove forward coolant tube (6) from EGR cooler (2). 8. Using Tool 6094, remove breather tube (7). 9. Using Tool 6094, remove rear coolant tube (8) from EGR cooler (2). 10. Remove EGR Transfer Connection Tube from casting, (if equipped). 11. Remove EGR cooler flange nuts (1). 12. Remove EGR cooler mount bolts. 13. Remove EGR cooler. Discard flange gasket. Installation Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6906 INSTALLATION EGR COOLER - 6.7L DIESEL WARNING: Locking constant tension hose clamps are used on the EGR cooler system hoses. When removing or installing, use only tools designed for servicing this type of clamp. Always wear safety glasses when servicing locking constant tension clamps. 1. Using a new gasket, position EGR cooler (2) on flange. 2. Install flange nuts (1). Tighten to 10 Nm (89 in. lbs.). 3. Install EGR cooler mounting bolts. Tighten to 10 Nm (89 in. lbs). 4. Install EGR crossover tube (5) and crossover tube clamp (4). Tighten clamp nut to 10 Nm (89 in. lbs.). 5. Install EGR Transfer Connection Tube into casting, (if equipped). Tighten clamp nut to 10 Nm (89 in. lbs.). CAUTION: Locking constant tension clamps will SNAP when released. NOTE: Locking constant tension clamps can be released using a suitable screwdriver. 6. Position locking constant tension clamp (1) on froward coolant tube (4) and install tube. 7. Using a suitable screwdriver (3), release constant tension clamp (1). 8. Position locking constant tension clamp on rear coolant tube and install tube. 9. Using a suitable screwdriver, release constant tension clamp 10. Position locking constant tension clamp on breather tube and install tube. 11. Using a suitable screwdriver, release constant tension clamp. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6907 EGR COOLER - 6.7L DIESEL - P/U 12. Install EGR Control Assembly, if equipped. Tighten mounting bolts to 24 Nm (18 ft. lbs.). 13. Install EGR Control Assembly electrical connector, (if equipped). 14. Fill coolant system. 15. Install engine cover. 16. Connect negative battery cable(s). 17. Start engine and check for coolant or exhaust leaks. Removal-Pick Up Models REMOVAL-PICK UP MODELS The EGR Cooler Bypass Valve Assembly (1) is mounted between the EGR crossover tube and the EGR cooler. Two mechanical cables (3) join the units together. An electrical drive servo (4) moves the cables (3) to operate a butterfly plate (2) within a cast manifold. Parts 1, 2, 3 and 4 are serviced as one entire assembly. Do not attempt to disassemble unit. 1. Disconnect and isolate both negative battery cables at both batteries. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6908 2. Remove four bolts (2) and remove EGR tube cover (1). 3. Loosen and remove two clamps (1) and (6) at ends of EGR Crossover Tube. 4. Remove clamp mounting bolt (3) at center of EGR Crossover Tube. 5. Remove EGR Crossover Tube (4). 6. Remove and discard gaskets (doughnuts) at each end of tube (2) and (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6909 7. Remove nuts (7) and remove upper heat shield (6). 8. Remove bolts (10), nut (8) and remove lower heat shield (9). 9. Remove bolts (5) and (14). 10. Separate casting (4) from casting (15) and discard gasket (3). 11. Disconnect electrical connector (1). 12. Remove bracket bolts (2) at outside of mounting bracket. 13. Remove bracket bolts at inside of mounting bracket. 14. Remove EGR cooler bypass valve assembly from engine. Installation-Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6910 1. Clean gasket mating surfaces on castings (4) and (15). 2. Position EGR cooler bypass valve assembly to engine. 3. Position new gasket (3) between castings (4) and (15). 4. Install bolts (5) and (14). Do not tighten these bolts at this time. 5. Install bracket bolts (2) at outside of mounting bracket. Do not tighten these bolts at this time. 6. Install bracket bolts at inside of mounting bracket. Do not tighten these bolts at this time. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6911 7. Tighten bolts (5) and (14) to 24 Nm (18 ft. lbs.) torque. 8. Tighten bracket bolts (2) at outside of mounting bracket to 24 Nm (18 ft. lbs.) torque. 9. Tighten bracket bolts at inside of mounting bracket to 24 Nm (18 ft. lbs.) torque. 10. Connect electrical connector (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6912 11. Clean each end of EGR crossover tube and its connection points of any old gasket material 12. Install new gaskets (doughnuts) (2) and (5) to each end of tube. 13. Position EGR crossover tube (4) to engine. 14. Position bolt (3) at center of EGR crossover tube. Install bolt loosely (finger tight). 15. First, tighten EGR tube clamp (1) to 10 Nm (7 ft. lbs.), then tighten clamp (6) to 10 Nm (7 ft. lbs.). 16. Tighten clamp bolt (3) to 10 Nm (7 ft. lbs.). 17. Install upper heat shield (6) and nuts (7). Tighten nuts to 24 Nm (18 ft. lbs.) torque. 18. Install lower heat shield (9), bolts (10), and nut (8). Tighten nut/bolts to 24 Nm (18 ft. lbs.) torque. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6913 19. Install EGR tube cover (1) and four bolts (2). 20. Connect and both negative battery cables to both batteries. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Diagrams EGR Temperature Sensor: Diagrams Component ID: 394 Component : SENSOR-EGR TEMPERATURE Connector: Name : SENSOR-EGR TEMPERATURE Color : # of pins : 2 Qualifier : (6.7L DC) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 EGR TEMPERATURE SENSOR SIGNAL K935 18DB Connector: Name : SENSOR-EGR TEMPERATURE Color : # of pins : 2 Qualifier : (6.7L DH/D1) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 EGR TEMPERATURE SENSOR SIGNAL K935 18DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Description and Operation > Operation-Cab/Chassis Models EGR Temperature Sensor: Description and Operation Operation-Cab/Chassis Models OPERATION-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near the EGR valve. The EGR temperature sensor is a negative temperature coefficient thermistor used to measure the temperature of the EGR gas flow after it exits the EGR cooler. The ECM (Engine Control Module) supplies 5-volts to the EGR temperature signal circuit. To determine the temperature of the EGR gas flow, the ECM monitors the change in voltage caused by changes in the resistance of the sensor. The ECM uses the exhaust gas recirculation temperature value for the engine protection system, and also for engine emissions control. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Description and Operation > Operation-Cab/Chassis Models > Page 6919 EGR Temperature Sensor: Description and Operation Operation-Pick Up Models OPERATION-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). A temperature probe (1) is located at the end of the sensor assembly (3). The EGR temperature sensor is a negative temperature coefficient thermistor used to measure the temperature of the EGR gas flow after it exits the EGR cooler. The ECM (Engine Control Module) supplies 5-volts to the EGR temperature signal circuit. To determine the temperature of the EGR gas flow, the ECM monitors the change in voltage caused by changes in the resistance of the sensor. The ECM uses the exhaust gas recirculation temperature value for the engine protection system, and also for engine emissions control. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Service and Repair > Removal EGR Temperature Sensor: Service and Repair Removal Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near EGR valve. 1. Disconnect electrical connector (2) at sensor. 2. Remove sensor (1) from EGR tube (6). Removal-Pick Up Models REMOVAL-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 6922 1. If equipped, remove four cover bolts (2) and remove EGR crossover tube cover (1). 2. If equipped, remove EGR valve cover (2). 3. A pigtail wiring harness connects sensor to engine wiring harness. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 6923 4. Unscrew nut (2) at intake manifold. 5. Disconnect sensor pigtail harness electrical connector from engine wiring harness and remove sensor assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 6924 EGR Temperature Sensor: Service and Repair Installation Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near the EGR valve. 1. Clean EGR crossover tube at sensor mounting point. 2. Check condition of the sensors metal gasket and replace if necessary. 3. Install sensor (1) to EGR tube (6). Tighten to 18 Nm (13 ft. lbs.). 4. Connect electrical connector (2) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 6925 1. A pigtail wiring harness (3) connects the sensor to the engine wiring harness. 2. Position sensor probe (1) into intake manifold. 3. Screw and tighten nut (2) into intake manifold. 4. Connect electrical connector (4) to engine wiring harness. 5. Install EGR valve cover (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 6926 6. Install EGR crossover tube cover (1) and four cover bolts (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Removal EGR Tube: Service and Repair Removal Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS 1. Disconnect and isolate both negative battery cables at batteries. 2. Remove four bolts (2) and EGR crossover tube cover (1). 3. Remove heat shield (2) over EGR valve (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Removal > Page 6931 4. Disconnect electrical connector (4) at EGR Temperature Sensor. 5. Loosen and remove two clamps (1) and (3) at ends of EGR Crossover Tube. 6. Remove "P" clamp mounting bolt (5) at center of EGR Crossover Tube. 7. Remove EGR Crossover Tube (2). 8. Remove and discard gaskets (doughnuts) at each end of tube. Removal-Pick Up Models REMOVAL-PICK UP MODELS 1. Disconnect and isolate both negative battery cables at batteries. 2. Remove four bolts (2) and EGR crossover tube cover (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Removal > Page 6932 3. Remove heat shield (2) over EGR valve (1). 4. Loosen and remove two clamps (1) and (6) at ends of EGR Crossover Tube. 5. Remove clamp mounting bolt (3) at center of EGR Crossover Tube. 6. Remove EGR Crossover Tube (4). 7. Remove and discard gaskets (doughnuts) at each end of tube (2) and (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Removal > Page 6933 EGR Tube: Service and Repair Installation Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Clean each end of EGR crossover tube, and its connection points of any old gasket material 2. Install new gaskets (doughnuts) to each end of tube. 3. Position EGR crossover tube (2) to engine. 4. Position "P" clamp (5) at center of EGR crossover tube. Install "P" clamp bolt loosely (finger tight). 5. First, tighten EGR tube clamp (1) to 10 Nm (7 ft. lbs.), then tighten clamp (3) to 10 Nm (7 ft. lbs.). 6. Tighten "P" clamp bolt (5) to 10 Nm (7 ft. lbs.). 7. Connect electrical connector (4) to EGR temperature sensor. 8. Install heat shield (2) over EGR valve (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Removal > Page 6934 9. Install cover (1) and four cover bolts (2). 10. Connect both negative battery cables to both batteries. Installation-Pick Up Models INSTALLATION-PICK UP MODELS 1. Clean each end of EGR crossover tube and its connection points of any old gasket material 2. Install new gaskets (doughnuts) (2) and (5) to each end of tube. 3. Position EGR crossover tube (4) to engine. 4. Position bolt (3) at center of EGR crossover tube. Install bolt loosely (finger tight). 5. First, tighten EGR tube clamp (1) to 10 Nm (7 ft. lbs.), then tighten clamp (6) to 10 Nm (7 ft. lbs.). 6. Tighten clamp bolt (3) to 10 Nm (7 ft. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Removal > Page 6935 7. Install heat shield (2) over EGR valve (1). 8. Install cover (1) and four cover bolts (2). 9. Connect both negative battery cables to both batteries. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Assembly-EGR Valve EGR Valve: Locations Assembly-EGR Valve Component ID: 14 Component : ASSEMBLY-EGR VALVE Connector: Name : ASSEMBLY-EGR VALVE Color : # of pins : 8 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 EGR SIGNAL NO. 3 K687 18DB/LB 3 EGR SIGNAL NO. 2 K685 18DB 4 EGR SIGNAL NO. 1 K683 18DB/GY 5 SENSOR GROUND K916 18BR/OR 6 EGR CONTROL NO. 3 K686 18GY/DB 7 EGR CONTROL NO. 2 K684 18DB/YL 8 EGR CONTROL NO. 1 K682 18DB/WT Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Assembly-EGR Valve > Page 6940 Connector: Name : ASSEMBLY-EGR VALVE Color : PINK # of pins : 8 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 EGR SIGNAL NO. 3 K687 18DB/LB 3 EGR SIGNAL NO. 2 K685 18DB 4 EGR SIGNAL NO. 1 K683 18DB/GY Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Assembly-EGR Valve > Page 6941 5 SENSOR GROUND K916 18BR/OR 6 EGR CONTROL NO. 3 K686 18GY/DB 7 EGR CONTROL NO. 2 K684 18DB/YL 8 EGR CONTROL NO. 1 K682 18DB/WT Component Location - 11 Connector: Name : ASSEMBLY-EGR VALVE Color : BLACK # of pins : 6 Qualifier : (GAS EXCEPT 5.7L HD) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Assembly-EGR Valve > Page 6942 Pin Description Circuit 1 EGR SIGNAL K34 20DB/LG 2 5 VOLT SUPPLY F856 20YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GROUND Z335 20BK/WT 5-6 EGR SOL CONTROL K35 20DB/VT Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Assembly-EGR Valve > Page 6943 EGR Valve: Locations Valve-EGR Airflow Control Component ID: 497 Component : VALVE-EGR AIRFLOW CONTROL Connector: Name : VALVE-EGR AIRFLOW CONTROL Color : # of pins : 4 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 EGR AIRFLOW CONTROL VALVE MOTOR (+) K158 18BR/YL 2 EGR AIRFLOW CONTROL VALVE MOTOR (-)K314 18BR 3 SMART POWER RELAY FEED F348 16PK/OR 4 SENSOR GROUND K971 18BR/PK Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Assembly-EGR Valve > Page 6944 Connector: Name : VALVE-EGR AIRFLOW CONTROL Color : # of pins : 4 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 EGR AIRFLOW CONTROL VALVE MOTOR (+) K158 18BR/YL 2 EGR AIRFLOW CONTROL VALVE MOTOR (-)K314 18BR 3 SMART POWER RELAY FEED F348 16PK/OR 4 SENSOR GROUND K971 18BR/PK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Assembly-EGR Valve > Page 6945 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams > Assembly-EGR Valve EGR Valve: Diagrams Assembly-EGR Valve Component ID: 14 Component : ASSEMBLY-EGR VALVE Connector: Name : ASSEMBLY-EGR VALVE Color : # of pins : 8 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 EGR SIGNAL NO. 3 K687 18DB/LB 3 EGR SIGNAL NO. 2 K685 18DB 4 EGR SIGNAL NO. 1 K683 18DB/GY 5 SENSOR GROUND K916 18BR/OR 6 EGR CONTROL NO. 3 K686 18GY/DB 7 EGR CONTROL NO. 2 K684 18DB/YL 8 EGR CONTROL NO. 1 K682 18DB/WT Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams > Assembly-EGR Valve > Page 6948 Connector: Name : ASSEMBLY-EGR VALVE Color : PINK # of pins : 8 Qualifier : (6.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 EGR SIGNAL NO. 3 K687 18DB/LB 3 EGR SIGNAL NO. 2 K685 18DB 4 EGR SIGNAL NO. 1 K683 18DB/GY Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams > Assembly-EGR Valve > Page 6949 5 SENSOR GROUND K916 18BR/OR 6 EGR CONTROL NO. 3 K686 18GY/DB 7 EGR CONTROL NO. 2 K684 18DB/YL 8 EGR CONTROL NO. 1 K682 18DB/WT Component Location - 11 Connector: Name : ASSEMBLY-EGR VALVE Color : BLACK # of pins : 6 Qualifier : (GAS EXCEPT 5.7L HD) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams > Assembly-EGR Valve > Page 6950 Pin Description Circuit 1 EGR SIGNAL K34 20DB/LG 2 5 VOLT SUPPLY F856 20YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GROUND Z335 20BK/WT 5-6 EGR SOL CONTROL K35 20DB/VT Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams > Assembly-EGR Valve > Page 6951 EGR Valve: Diagrams Valve-EGR Airflow Control Component ID: 497 Component : VALVE-EGR AIRFLOW CONTROL Connector: Name : VALVE-EGR AIRFLOW CONTROL Color : # of pins : 4 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 EGR AIRFLOW CONTROL VALVE MOTOR (+) K158 18BR/YL 2 EGR AIRFLOW CONTROL VALVE MOTOR (-)K314 18BR 3 SMART POWER RELAY FEED F348 16PK/OR 4 SENSOR GROUND K971 18BR/PK Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams > Assembly-EGR Valve > Page 6952 Connector: Name : VALVE-EGR AIRFLOW CONTROL Color : # of pins : 4 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 EGR AIRFLOW CONTROL VALVE MOTOR (+) K158 18BR/YL 2 EGR AIRFLOW CONTROL VALVE MOTOR (-)K314 18BR 3 SMART POWER RELAY FEED F348 16PK/OR 4 SENSOR GROUND K971 18BR/PK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams > Assembly-EGR Valve > Page 6953 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve EGR Valve: Service and Repair EGR Valve Removal-Pick Up Models REMOVAL-PICK UP MODELS 1. Disconnect and isolate both negative battery cables at both batteries. 2. Remove four bolts (2) and remove EGR crossover tube cover (1). 3. Remove EGR valve heat shield (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6956 4. Loosen (only) clamp (6). Remove clamp (1) at end of EGR Crossover Tube. 5. Remove bolt (3) at center of EGR Crossover Tube. 6. Disconnect electrical connector at end of valve assembly. 7. Remove two EGR valve assembly mounting bolts and two nuts (1). 8. Remove EGR valve assembly (2) from intake connector (3) by prying up. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6957 9. Remove crossover tube doughnut gasket (1) and clean EGR valve. Also clean end of EGR tube of any old gasket material. 10. Remove two gaskets on bottom EGR valve (4). Clean bottom of EGR valve and top of its intake connection point of any old gasket material. 11. To prevent contaminants, cover the exposed opening at intake connection. Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS 1. Disconnect and isolate both negative battery cables at both batteries. 2. Remove four bolts (2) and remove EGR crossover tube cover (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6958 3. Remove EGR valve heat shield (2). 4. Disconnect electrical connector (5) at EGR Actuator. 5. Loosen (only) clamp (1). Remove clamp (3) at end of EGR Crossover Tube. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6959 6. Loosen (only) bolt at "P" clamp (5) at center of EGR Crossover Tube. 7. Remove two EGR valve assembly mounting bolts and two nuts (1). 8. Remove EGR valve assembly (2) from intake connector (3) by prying up. 9. Remove crossover tube doughnut gasket (1) and clean EGR valve. Also clean end of EGR tube of any old gasket material. 10. Remove two gaskets on bottom EGR valve (4). Clean bottom of EGR valve and top of its intake connection point of any old gasket material. 11. To prevent contaminants, cover the exposed opening at intake connection. Cleaning CLEANING Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6960 6.7L EGR VALVE CLEANING PROCEDURE 1. Remove EGR valve assembly from engine. 2. Remove four mounting screws (4) from EGR valve motor (3). 3. Remove valve motor (6) and shim (5) from EGR valve housing (1). Motor (6) and shim (5) must be kept for reassembly. The original EGR valve motor and its shim must be reinstalled onto the original EGR valve housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6961 4. Use two fingers to press down on valve spring retainer (3) to unlock two valve keepers (2). If valve keepers will not release using finger pressure, locate a 5/8 inch deep socket to the spring retainer (3). Gently tap on the socket with a small hammer to release keepers, then use two fingers and press for keeper removal. 5. Remove valve spring retainer (3) and valve spring (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6962 6. Lightly press on valve stem (1) about 3/8 inch to force valve faces from valve seats. 7. Using a small nylon scrubbing brush, lightly brush away loose soot from EGR valve housing. 8. The EGR valve shaft stem (3) is comprised of two valve faces (1) on two valve seats. Using the same small nylon scrubbing brush, lightly brush away loose soot from stem (3), valve seat (2) and also from valve seat on EGR valve housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6963 9. Completely submerge valve housing using a mixture of hot tap water and MOPAR(R) EGR System Cleaner (ESC). Mix cleaning solution 1 part ESC and 4 parts water. Allow cleaning solution to soak for 1 hour. 10. Remove assembly from cleaning solution. Completely remove remaining soot from valve stems, both valve seats, and both valve faces using a small nylon scrubbing brush. Dispose of cleaning solution per local governmental regulations. 11. Rinse EGR valve housing in hot tap water until all cleaning solution is rinsed clean. Dry completely. 12. Assemble valve spring (2) and retainer (3) to housing. 13. Position valve keepers (2). Press down on retainer (3) until groves on valve keepers lock into valve stem (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6964 14. Install original shim (5) and original motor (6) to housing. Motor is not indexed. Rotate motor until its electrical connector is pointed towards front of vehicle. Install four mounting screws (7). 15. Install EGR valve assembly to engine. Installation-Pick Up Models INSTALLATION-PICK UP MODELS 1. Install new gasket (1) to end of EGR tube. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6965 2. Position EGR valve assembly (2) and two new gaskets to intake connection (3). 3. Install two EGR valve mounting bolts (1) and two nuts (1). Tighten four nuts/bolts finger tight only. 4. Install and lightly tighten two clamps (1) and (6) at ends of EGR Crossover Tube. 5. Install bolt (3) finger tight only. 6. Tighten clamp (6) first to 10 Nm. (7 ft. lbs.), then tighten clamp (1) to 10 Nm. (7 ft. lbs.). 7. Tighten tube bolt (3) to 10 Nm (7 ft. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6966 8. Tighten two EGR valve mounting bolts and two nuts (1) to 24 Nm (18 ft. lbs.). Tighten these four nuts/bolts in an alternating, criss-cross fashion. 9. Connect electrical connector to EGR Actuator. 10. Install EGR crossover tube cover (1) and four bolts (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6967 11. Install EGR valve heat shield (2). Tighten bolts/nuts to 10 Nm (7 ft. lbs.). 12. Connect both negative battery cables to both batteries. Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Install new gasket (1) to end of EGR tube. 2. Position EGR valve assembly (2) and two new gaskets to intake connection (3). 3. Install two EGR valve mounting bolts (1) and two nuts (1). Tighten four nuts/bolts finger tight only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6968 4. Install and lightly tighten two clamps (1) and (3) at ends of EGR Crossover Tube. 5. Install "P" clamp bolt (5) finger tight only. 6. Tighten clamp (1) first to 10 Nm. (7 ft. lbs.), then tighten clamp (3) to 10 Nm. (7 ft. lbs.). 7. Tighten "P" clamp bolt (5) to 10 Nm (7 ft. lbs.). 8. Tighten two EGR valve mounting bolts and two nuts (1) to 24 Nm (18 ft. lbs.). Tighten these four nuts/bolts in an alternating, criss-cross fashion. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6969 9. Connect electrical connector (5) to EGR Actuator. 10. Install EGR crossover tube cover (1) and four bolts (2). 11. Install EGR valve heat shield (2). Tighten bolts/nuts to 10 Nm (7 ft. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6970 12. Connect both negative battery cables to both batteries. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6971 EGR Valve: Service and Repair EGR Valve Air Flow Control Removal REMOVAL The EGR Air Flow Control Valve (5) is bolted to the end of the air intake connection (2). 1. Remove clamp for charge air cooler duct at point (5). Disconnect air cooler duct at this point. 2. Disconnect electrical connector at point (2). This point is located at bottom/inside of air control valve (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6972 3. Remove four mounting bolts (4) and (6) and remove air flow control valve (5). 4. Remove gasket (3) and discard. Installation INSTALLATION The EGR Air Flow Control Valve (5) is bolted to the end of the air intake connection (2). 1. Obtain new gasket (3). Before positioning new gasket (3), be sure to clean mating surfaces at top of air flow control valve and bottom of air intake connection (2). 2. Install four mounting bolts (4) and (6). Tighten four bolts to 18 Nm (13 ft. lbs.) (160 in. lbs.) torque. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve > Page 6973 3. Connect electrical connector at point (2). 4. Connect air cooler duct to bottom of air flow control valve. Install and tighten duct clamp. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal Pressure Feedback Exhaust Sensor: Service and Repair Removal REMOVAL 1. Disconnect exhaust gas pressure sensor electrical connector (1). 2. Using a 6 point deepwell socket, remove exhaust gas sensor (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal > Page 6978 Pressure Feedback Exhaust Sensor: Service and Repair Installation INSTALLATION 1. Using a 6 point deepwell socket, install exhaust gas pressure sensor. 2. Tighten sensor to 18 Nm (13 ft. lbs.). 3. Connect exhaust gas pressure sensor electrical connector (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Filter > Component Information > Description and Operation Crankcase Filter: Description and Operation DESCRIPTION The Closed Crankcase Ventilation System (CCV) consists of several parts to make it functional. One part is the filter. The filter is serviceable and prevents oil mist from entering the discharge tube of the CCV system. It is not cleaned, but replaced at 60,000 mile intervals. The crankcase breather assembly is integrated into the cylinder head cover (3) and is serviced separately. The external fittings (2) to the breather tube and breather drain tube are serviceable. The crankcase breather assembly is integrated into the cylinder head cover and corresponding breather cover. Crankcase gasses travel into the breather cavity under the breather cover where they pass through a filtering media (serviceable maintenance component) which separates the oil from the crankcase gasses. The oil drains back into the engine block through two hoses (2) on the left side of the engine. The crankcase gasses are directed through the Crankcase Depression Regulator (CDR) valve which allows the system to maintain a constant positive pressure in the crankcase. The CDR valve is a non-serviceable component located on the underside of the breather cover. Clean crankcase gasses flow from the CDR valve into the fresh air side of the turbocharger compressor. The closed crankcase ventilation valve is used to vent the crankcase gases back into the intake of engine. If the crankcase ventilation filter becomes too restrictive, under high intake vacuum situations, the closed crankcase ventilation prevents the engine from syphoning crankcase gases/oil from the crankcase of the engine. The closed crankcase ventilation valve is located under the crankcase ventilation filter cover at the top of the engine. TESTING 1. If troubleshooting high crankcase pressure, the following items can be causing the closed crankcase ventilation valve to close during engine Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Filter > Component Information > Description and Operation > Page 6983 operation: High air intake restriction. Check for high intake restriction - A restricted crankcase ventilation filter. Change the filter - A malfunctioning or misassembled closed crankcase ventilation valve. Check the valve operation and change if necessary 2. The closed crankcase ventilation valve should allow crankcases gases to flow when the engine is not running and/or removed from the engine. NOTE: Application of air can be applied either to the inlet or outlet of the closed crankcase ventilation valve. 3. A small amount of air can be blown through the closed crankcase ventilation valve (less than 34 kPa [5 psi]) to check the closed crankcase ventilation valve. 4. If air does not go through the closed crankcase ventilation valve, replace the valve. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Filter > Component Information > Service and Repair > Removal Crankcase Filter: Service and Repair Removal REMOVAL 1. Using hose clamp pliers, loosen the breather plumbing from the breather cover connections. 2. Carefully remove the breather hoses (2) from the breather cover assembly (3). 3. Remove the capscrews surrounding the parameter of the breather cover (3). 4. Separate the breather cover (3) assembly from the cylinder head cover (1). FILTER ELEMENT REMOVAL 1. With the breather cover removed, remove the filter element from the cylinder head cover cavity by lifting the element straight up from its sealing surface. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Filter > Component Information > Service and Repair > Removal > Page 6986 Crankcase Filter: Service and Repair Installation FILTER ELEMENT INSPECTION 1. Inspect the crankcase breather assembly by ensuring the oil drain hoses are not kinked or cracked. 2. Inspect all external hose connections for signs of leakage, repair where necessary. Inspect the breather for cracks or damage. 3. Inspect the filter element sealing surface for gouges or cracks; this surface should be smooth and free of abrasions. FILTER ELEMENT INSTALLATION 1. Clean the filter sealing surface on the cylinder head cover with a clean shop towel. 2. Install the new filter element, lubrication of the new sealing surface is not recommended. 3. Press the new filter into the cylinder head cover cavity until fully seated. 4. Install the breather cover assembly. BREATHER COVER INSTALLATION 1. Inspect the filter element for proper installation. The filter should be completely seated around the circumference of the sealing surface. 2. Install the breather cover to the cylinder head cover. 3. Install the capscrews surrounding the breather cover. 4. Install the breather drain hoses onto the hose barbs. Do not damage or hose connection during installation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Pressure Sensor > Component Information > Locations Crankcase Pressure Sensor: Locations Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Pressure Sensor > Component Information > Locations > Page 6990 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Pressure Sensor > Component Information > Locations > Page 6991 Crankcase Pressure Sensor: Diagrams Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Pressure Sensor > Component Information > Locations > Page 6992 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Pressure Sensor > Component Information > Locations > Page 6993 Crankcase Pressure Sensor: Description and Operation OPERATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). The CP sensor monitors crankcase pressure that builds up as the result of combustion gas blow-by. The Engine Control Module (ECM) uses data from the CP sensor to determine the condition of the crankcase breather (ventilation) filter. The ECM can also determine if a crankcase breather (ventilation) filter is present. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal Crankcase Pressure Sensor: Service and Repair Removal REMOVAL The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Remove mounting screw (6). 2. Disconnect electrical connector (7). 3. Remove sensor (5) from valve cover (4). 4. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal > Page 6996 Crankcase Pressure Sensor: Service and Repair Installation INSTALLATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Check condition of sensor O-ring. 2. Install sensor (5) into valve cover (4). 3. Install mounting screw (6). Tighten to 3 Nm (27 in. lbs.) torque. 4. Connect electrical connector (7). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations Positive Crankcase Ventilation Valve: Locations PCV FILTER The crankcase breather/filter is no longer used with the 3.9L, 5.2L or 5.9L engine. PCV VALVE All 3.9L V-6 and 5.2L/5.9L V-8 gas powered engines are equipped with a closed crankcase ventilation system and a positive crankcase ventilation (PCV) valve. The 8.0L V-10 engine is not equipped with a PCV valve. Refer to Crankcase Ventilation System-8.0L V-10 Engine for information. Fig. 4 Typical PCV Valve/Hose (Non-California Shown) This system consists of a PCV valve mounted on the cylinder head (valve) cover with a hose extending from the valve to the intake manifold. Another hose connects the opposite cylinder head (valve) cover to the air cleaner housing to provide a source of clean air for the system. A separate crankcase breather/filter is not used. Fig. 5 Typical Closed Crankcase Ventilation System The PCV system operates by engine intake manifold vacuum. Filtered air is routed into the crankcase through the air cleaner hose. The metered air, along with crankcase vapors, are drawn through the PCV valve and into a passage in the intake manifold. The PCV system manages crankcase Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 7000 pressure and meters blow by gases to the intake system, reducing engine sludge formation. The PCV valve contains a spring loaded plunger. This plunger meters the amount of crankcase vapors routed into the combustion chamber based on intake manifold vacuum. Fig. 6 Engine Off Or Engine Pop-Back - No Vapor Flow When the engine is not operating or during an engine pop-back, the spring forces the plunger back against the seat. This will prevent vapors from flowing through the valve. Fig. 7 High Intake Manifold Vacuum - Minimal Vapor Flow During periods of high manifold vacuum, such as idle or cruising speeds, vacuum is sufficient to completely compress spring. It will then pull the plunger to the top of the valve. In this position there is minimal vapor flow through the valve. Fig. 8 High Intake Manifold Vacuum - Maximum Vapor Flow During periods of moderate manifold vacuum, the plunger is only pulled part way back from inlet. This results in maximum vapor flow through the valve. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 7006 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 7007 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 7008 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 7009 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 7010 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 7011 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 7012 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 7013 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 399 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 7016 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 20BR/LB Pin Description Circuit 1 EXHAUST TEMPERATURE SENSOR 1 SIGNAL K185 18BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 7017 2 SENSOR GROUND K900 20BD/DG 2 SENSOR GROUND K900 18BD/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 7018 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 400 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 7019 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 20BR/DB Pin Description Circuit 1 EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL K186 18BR/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 7020 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 7021 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 401 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 7022 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 20BR/DG Pin Description Circuit 1 EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL K372 18BR/DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 7023 2 SENSOR GROUND K900 20DB/DG 2 SENSOR GROUND K900 18DB/DG Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 7026 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 7029 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations Crankcase Pressure Sensor: Locations Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 7033 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 7034 Crankcase Pressure Sensor: Diagrams Component ID: 391 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 SENSOR GROUND K916 18BR/OR 3 CRANKCASE SENSOR SIGNAL K926 18DB/GY Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 7035 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 7036 Crankcase Pressure Sensor: Description and Operation OPERATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). The CP sensor monitors crankcase pressure that builds up as the result of combustion gas blow-by. The Engine Control Module (ECM) uses data from the CP sensor to determine the condition of the crankcase breather (ventilation) filter. The ECM can also determine if a crankcase breather (ventilation) filter is present. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal Crankcase Pressure Sensor: Service and Repair Removal REMOVAL The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Remove mounting screw (6). 2. Disconnect electrical connector (7). 3. Remove sensor (5) from valve cover (4). 4. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Service and Repair > Removal > Page 7039 Crankcase Pressure Sensor: Service and Repair Installation INSTALLATION The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). 1. Check condition of sensor O-ring. 2. Install sensor (5) into valve cover (4). 3. Install mounting screw (6). Tighten to 3 Nm (27 in. lbs.) torque. 4. Connect electrical connector (7). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Diagrams EGR Temperature Sensor: Diagrams Component ID: 394 Component : SENSOR-EGR TEMPERATURE Connector: Name : SENSOR-EGR TEMPERATURE Color : # of pins : 2 Qualifier : (6.7L DC) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 EGR TEMPERATURE SENSOR SIGNAL K935 18DB Connector: Name : SENSOR-EGR TEMPERATURE Color : # of pins : 2 Qualifier : (6.7L DH/D1) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 EGR TEMPERATURE SENSOR SIGNAL K935 18DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Description and Operation > Operation-Cab/Chassis Models EGR Temperature Sensor: Description and Operation Operation-Cab/Chassis Models OPERATION-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near the EGR valve. The EGR temperature sensor is a negative temperature coefficient thermistor used to measure the temperature of the EGR gas flow after it exits the EGR cooler. The ECM (Engine Control Module) supplies 5-volts to the EGR temperature signal circuit. To determine the temperature of the EGR gas flow, the ECM monitors the change in voltage caused by changes in the resistance of the sensor. The ECM uses the exhaust gas recirculation temperature value for the engine protection system, and also for engine emissions control. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Description and Operation > Operation-Cab/Chassis Models > Page 7045 EGR Temperature Sensor: Description and Operation Operation-Pick Up Models OPERATION-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). A temperature probe (1) is located at the end of the sensor assembly (3). The EGR temperature sensor is a negative temperature coefficient thermistor used to measure the temperature of the EGR gas flow after it exits the EGR cooler. The ECM (Engine Control Module) supplies 5-volts to the EGR temperature signal circuit. To determine the temperature of the EGR gas flow, the ECM monitors the change in voltage caused by changes in the resistance of the sensor. The ECM uses the exhaust gas recirculation temperature value for the engine protection system, and also for engine emissions control. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal EGR Temperature Sensor: Service and Repair Removal Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near EGR valve. 1. Disconnect electrical connector (2) at sensor. 2. Remove sensor (1) from EGR tube (6). Removal-Pick Up Models REMOVAL-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 7048 1. If equipped, remove four cover bolts (2) and remove EGR crossover tube cover (1). 2. If equipped, remove EGR valve cover (2). 3. A pigtail wiring harness connects sensor to engine wiring harness. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 7049 4. Unscrew nut (2) at intake manifold. 5. Disconnect sensor pigtail harness electrical connector from engine wiring harness and remove sensor assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 7050 EGR Temperature Sensor: Service and Repair Installation Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near the EGR valve. 1. Clean EGR crossover tube at sensor mounting point. 2. Check condition of the sensors metal gasket and replace if necessary. 3. Install sensor (1) to EGR tube (6). Tighten to 18 Nm (13 ft. lbs.). 4. Connect electrical connector (2) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 7051 1. A pigtail wiring harness (3) connects the sensor to the engine wiring harness. 2. Position sensor probe (1) into intake manifold. 3. Screw and tighten nut (2) into intake manifold. 4. Connect electrical connector (4) to engine wiring harness. 5. Install EGR valve cover (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 7052 6. Install EGR crossover tube cover (1) and four cover bolts (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Description and Operation Exhaust Pressure Differential Sensor: Description and Operation DESCRIPTION The Exhaust Differential Pressure Sensor is remotely mounted on the transmission housing. Two pressure tubes measure pressure before and after the Diesel Particulate Filter (DPF)/Diesel Oxidation Catalyst (DOC). The sensor is critical for fail-safe of regeneration strategy, because it interprets high pressure drops as possible high soot loads. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Differential Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect electrical connector. 3. Disconnect hoses at pressure differential pressure sensor. 4. Remove mounting bolt and differential pressure sensor. 5. Remove mounting bolts (1). 6. Remove pressure differential pressure tubing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal > Page 7058 Exhaust Pressure Differential Sensor: Service and Repair Installation INSTALLATION 1. Install differential pressure tubing, if removed. Tighten fittings to 30 Nm (22 ft. lbs.). 2. Position differential pressure sensor (1). 3. Install mounting nuts (5) and bolts. Tighten to 10 Nm (89 in. lbs.). 4. Install hose (2) to the rear DPF tubing. 5. Install hose (3) to the front DPF tubing. 6. Connect electrical connector (6). 7. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal Pressure Feedback Exhaust Sensor: Service and Repair Removal REMOVAL 1. Disconnect exhaust gas pressure sensor electrical connector (1). 2. Using a 6 point deepwell socket, remove exhaust gas sensor (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal > Page 7063 Pressure Feedback Exhaust Sensor: Service and Repair Installation INSTALLATION 1. Using a 6 point deepwell socket, install exhaust gas pressure sensor. 2. Tighten sensor to 18 Nm (13 ft. lbs.). 3. Connect exhaust gas pressure sensor electrical connector (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL PRESSURES Fuel Pump/Gear Pump (low pressure) ................................................................................................................................ 551.5 - 1241 KPA (80 - 180 psi) Injection Pump ..................................................................................................................................... ............................ 200 - 1800 bar (2900 - 26107 psi) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test Fuel Pressure: Testing and Inspection Fuel Pump Return Flow Test *FUEL PUMP RETURN FLOW TEST 1. FUEL PUMP RETURN FLOW TEST Using the scan tool, idle the engine and measure the rail pressure and determine if the rail pressure is excessive (above 185,00 kpa/26,831 psi). If it is, troubleshoot for excessive rail pressure first. Remove the banjo bolt from the pressure-limiting valve on the fuel rail. Install fuel system test fitting 9013 into the pressure-limiting valve. Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose into a container Perform the tests listed below to determine if the pressure-limiting valve is leaking. a. Operate the engine at idle and watch for fuel flow into the fuel container. b. Operate the engine at idle and actuate the high pressure safety valve test with the scan tool. Watch for fuel flow into the fuel container. If fuel flows into the fuel container, replace the pressure-limiting valve. If fuel does not leak from the pressure-limiting valve, the test is complete. NOTE: Do not drive the vehicle with any portion of this test kit installed Operate the engine until the engine is at operating temperature. Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing Install fuel system test fitting 9012 in place of the banjo connector. Install a piece of fuel line onto the test fitting and put the open end into the graduated cylinder . Start the engine and let it idle for one minute. Measure the amount of fuel in the graduated cylinder. If the flow is less than 1000ml/minute at idle, the test has successfully passed. If the flow is greater than 1000ml/minute at idle, replace the fuel injection pump. Retest to confirm repair. View Repair Repair - Test Complete. - Perform POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 7070 Fuel Pressure: Testing and Inspection High Pressure Fuel Pump Performance Test *HIGH PRESSURE FUEL PUMP PERFORMANCE TEST If the engine will run do the following: 1. Monitor rail pressure with scan tool while the engine is at idle. 2. Compare the fuel pressure set point with the actual fuel pressure reading. 3. If actual fuel pressure reading fluctuates more than ± 500 psi from the set point, then replace the Fuel Control Actuator (FCA). NOTE: After the actuator is removed, check for debris or corrosion on the FCA. If debris or corrosion is found, replace the entire Fuel Injection Pump. 4. Turn off engine. 5. Disconnect the FCA harness 6. Disconnect high pressure fuel line from fuel rail and route the high pressure fuel line into a graduated cylinder. 7. Crank the engine until fuel exits this line. This will not be high pressure fuel. 8. Crank the engine for three (3) 10 second intervals (Note: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter). Fuel flow specification s based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL If the engine is a no start do the following: 1. Remove fuel pump to rail high pressure fuel line. 2. Inspect the fuel pump outlet port for rust, debris, or other signs of contamination. 3. Replace pump if any contamination is found. Check for source of water in fuel or debris in fuel to prevent future complaints. If no contamination is found continue to step 4. 4. Disconnect the Fuel Control Actuator (FCA). 5. Disconnect the high pressure fuel line from the fuel rail and route the high pressure fuel line to a graduated cylinder. 6. Crank the engine until fuel exits this line. This will not be high pressure fuel. 7. Crank the engine for three (3) 10 seconds intervals. NOTE: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter. Fuel flow specification's based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 7071 Fuel Pressure: Testing and Inspection In-Tank Fuel Lift Pump Flow/Diagnostic Test Procedure *IN-TANK FUEL LIFT PUMP FLOW/DIAGNOSTIC TEST PROCEDURE 1. Using the Scan tool, check for DTCs. Troubleshoot any active DTCs before performing this test. 2. Disconnect the wiring harness from the lift pump at the fuel tank module connector and inspect the pins for damage. Fix or replace any damaged component. 3. Connect a voltmeter between the fuel lift pump supply and return pins at the fuel tank module connector. 4. Turn the ignition to the on position. Use the Scan tool to actuate the fuel lift pump, record the voltage on the voltmeter. 5. If the voltage is greater than 11.5 volts, go to step 14. If the voltage is less than 11.5 volts, go to step 6 6. Using a voltmeter, measure the battery voltage to determine that the voltage is greater than 11.5 volts. If the voltage is greater than 11.5 volts, go to step 7. If the voltage is not greater than 11.5 volts, troubleshoot for low battery voltage. 7. Remove the fuel lift pump relay from the PDC. Use a voltmeter to measure the voltage at the fuel lift pump relay voltage supply pin in the PDC. If the voltage is greater than 11.5 volts, go to step 8. If the voltage is not greater than 11.5 volts, fix or replace the harness. 8. Remove the fuel lift pump relay from the PDC. Install a spare relay in place of the fuel lift pump relay. Using the Scan tool, actuate the fuel lift pump. Use a voltmeter to measure the voltage between the fuel lift pump supply and return pins at the fuel tank module connector while the fuel lift pump is actuated. If the voltage is greater than 11.5 volts, replace the fuel lift pump relay. If the voltage is not greater than 11.5 volts, go to step 9. 9. Disconnect the wiring harness from the fuel tank module. Remove the lift pump relay from the PDC. Using an Ohmmeter, measure the resistance of the fuel lift pump power supply wire between the PDC relay output pin and the fuel tank module connector. If the resistance is less than 10 ohms, go to step 10. If it is greater than 10 ohms, fix or replace the harness. 10. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using a voltmeter, measure the voltage between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the voltage is less than 1 volt, go to step 11. If the voltage is greater than 1 volt, fix or replace the harness. 11. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using an ohmmeter, measure the resistance between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the resistance is less than 10 ohms, fix or replace the harness. If the resistance is greater than 10 ohms, go to step 12. 12. Disconnect the wiring harness from the fuel tank module. Using an Ohmmeter, measure the resistance of the fuel lift pump ground wire between the fuel tank module connector and battery negative. If the resistance is less than 10 ohms, go to step 13. If the resistance is greater than 10 ohms, fix or replace the harness. 13. Disconnect the wiring harness from the fuel tank module. Using a voltmeter, measure the voltage between the fuel lift pump ground wire and battery negative. If the voltage is less than 1 volt, go to step 14. If the voltage is greater than 1 volt, fix or replace the harness. 14. Reconnect the lift pump connector. FLOW TEST. 1. Remove the fuel pump supply banjo fitting from the fuel injection pump. 2. Install fuel system test fitting 9863 onto the end of the quick connect line going to the fuel injection pump. 3. Connect one end of a section of fuel hose to the test fitting. 4. Put the other end of the fuel hose into an empty fuel container. 5. Use the scan tool to actuate the fuel lift pump. 6. While the lift pump is running, move the fuel hose from the fuel canister into a 1000ml graduated cylinder for 10 seconds. 7. Read and record the amount of fuel in the graduated cylinder after 10 seconds. 8. If you have more than 570ml in the graduated cylinder after 10 seconds, the test has successfully passed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 7072 9. If you have less than 570ml of fuel in the graduated cylinder, inspect the fuel supply line from the fuel tank to the fuel filter housing and the fuel supply line between the fuel filter housing and the high pressure fuel pump for signs of damage, replace as necessary. If no damage is found, replace the fuel filter and retest. 10.Verify the Screened Banjo Bolt at the outlet of the fuel filter is free of debris. If debris is found, rinse screen with water, blow dry and reinstall. Retest vehicle. If flow meets specification then trace back the source of debris, if flow is still below spec repair damaged component. 11. If reading is still less than 570ml in 10 seconds, remove the fuel tank and fuel tank module. Inspect for damage and/or debris in and around the fuel tank module. If module is damaged, replace and retest. 12. If the module is not damaged, replace the fuel lift pump and retest to confirm fix. Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 7079 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 7080 Accelerator Pedal Position Sensor: Diagrams Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 7081 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 7084 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) provides the Engine Control Module (ECM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 7087 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal Air Filter Element: Service and Repair Removal REMOVAL Testing Air Cleaner Element using Filter Minder(TM) Do not attempt to unnecessarily remove top of air cleaner housing for air cleaner element inspection on diesel engines. The air cleaner (filter) housing (5) is equipped with an air Filter Minder(TM) gauge (3). This air flow restriction gauge will determine when air cleaner element is restricted and should be replaced. The Filter Minder(TM) (5) consists of a diaphragm and calibrated spring sealed inside of a plastic housing. A yellow colored disc (2) attached to diaphragm moves along a graduated scale on side of Filter Minder. After the engine has been shut off, a ratcheting device located within Filter Minder will hold yellow disc at highest restriction that air cleaner element has experienced. A drop in air pressure due to an air cleaner element restriction moves diaphragm and yellow disc will indicate size of air drop. CAUTION: Certain engine degreasers or cleaners may discolor or damage plastic housing of Filter Minder. Cover and tape Filter Minder if any engine degreasers or cleaners are to be used. To test, turn engine off. If yellow disc (2) has reached red colored zone (3) on graduated scale, air cleaner element should be replaced. Refer to Removal / Installation. Resetting Filter Minder: After air cleaner (filter) element has been replaced, press rubber button on top of Filter Minder. This will allow yellow Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 7093 colored disc to reset. After button has been pressed, yellow disc should spring back to UP position. If Filter Minder gauge has reached red colored zone, and after an examination of air cleaner (filter) element, element appears to be clean, high reading may be due to a temporary condition such as snow build-up at air intake. Temporary high restrictions may also occur if air cleaner (filter) element has gotten wet such as during a heavy rain or snow. If this occurs, allow element to dry out during normal engine operation. Reset rubber button on top of Filter Minder and retest after element has dried. Filter Removal 1. The housing cover is equipped with spring clips and is hinged with plastic tabs. Unlatch clips from top of air cleaner housing and tilt housing cover up for cover removal. 2. Remove air cleaner element from air cleaner housing (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 7094 Air Filter Element: Service and Repair Installation INSTALLATION 1. Before installing new air cleaner element (filter), clean inside of air cleaner housing. 2. Position air cleaner cover to tabs on front of air cleaner housing. Latch spring clips to seal cover to housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 7098 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 7099 Air Flow Meter/Sensor: Diagrams Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 7100 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 7101 Air Flow Meter/Sensor: Description and Operation OPERATION The Mass Airflow (MAF) sensor is a frequency based device. A constant voltage is applied to a heated wire on the sensor. This wire is positioned in the air cleaner air stream and is heated by the electrical current that the voltage produces. As air flows across it, it cools down. The heated wire or film is a positive temperature coefficient resistor. This means that its resistance drops when its temperature drops. The drop in resistance allows more current to flow through it in order to maintain the programmed temperature. This current is changed to a frequency which is sent to the Engine Control Module (ECM) and interpreted as air flow. Adjustments for air temperature and humidity are taken into consideration because they also affect the temperature of the heated wire or film. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL The Mass Airflow Sensor (5) is located on the air cleaner cover (8). 1. Disconnect electrical connector (6) at sensor. 2. Remove two mounting screws (4). 3. Remove sensor from air cleaner cover. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 7104 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (4). 4. Install electrical connector (6). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Locations > Actuator-Fuel Control Fuel Inlet Metering Valve: Locations Actuator-Fuel Control Component ID: 4 Component : ACTUATOR-FUEL CONTROL Connector: Name : ACTUATOR-FUEL CONTROL Color : # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL CONTROL ACTUATOR DRIVER K604 18BR/TN Pin Description Circuit 1 FUEL CONTROL ACTUATOR DRIVER K365 18DB/BR 2 FUEL CONTROL ACTUATOR RETURN K65 18BR/LB 2 FUEL CONTROL ACTUATOR RETURN K366 18BR/LB Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Locations > Actuator-Fuel Control > Page 7110 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Locations > Actuator-Fuel Control > Page 7111 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Locations > Actuator-Fuel Control > Page 7112 Fuel Inlet Metering Valve: Locations Actuator - Fuel Control The Fuel Control Actuator (FCA) (3) is located at the rear of the high-pressure, fuel injection pump. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Locations > Page 7113 Fuel Inlet Metering Valve: Diagrams Component ID: 4 Component : ACTUATOR-FUEL CONTROL Connector: Name : ACTUATOR-FUEL CONTROL Color : # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL CONTROL ACTUATOR DRIVER K604 18BR/TN Pin Description Circuit 1 FUEL CONTROL ACTUATOR DRIVER K365 18DB/BR 2 FUEL CONTROL ACTUATOR RETURN K65 18BR/LB 2 FUEL CONTROL ACTUATOR RETURN K366 18BR/LB Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Locations > Page 7114 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Locations > Page 7115 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Description and Operation > Valve-Cascade Overflow Fuel Inlet Metering Valve: Description and Operation Valve-Cascade Overflow Description DESCRIPTION NOTE: The cascade overflow valve is not serviced separately. The cascade overflow valve (4) is located on the top/rear side of the fuel injection pump. Operation OPERATION When the fuel control actuator (FCA) is opened, the maximum amount of fuel is being delivered to the fuel injection pump. The cascade valve regulates how much excess fuel is used for lubrication of the injection pump, and is also used to route excess fuel through the drain circuit and back into the fuel tank. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Description and Operation > Valve-Cascade Overflow > Page 7118 Fuel Inlet Metering Valve: Description and Operation Actuator - Fuel Control Description DESCRIPTION The Fuel Control Actuator (FCA) (3) is located at the rear of the high-pressure, fuel injection pump. Operation OPERATION The Fuel Control Actuator (FCA) is an electronically controlled solenoid valve. The ECM controls the amount of fuel that enters the high-pressure pumping chambers by opening and closing the FCA based on a demanded fuel pressure. When the FCA is opened, the maximum amount of fuel is being supplied to the fuel injection pump. Any fuel that does not enter the injection pump is directed to the cascade overflow valve. The cascade overflow valve regulates how much excess fuel is used for lubrication of the pump and how much is returned to the fuel tank through the drain manifold. An audible click from the FCA is normal when operating the key from the ON to the OFF position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Service and Repair > Removal Fuel Inlet Metering Valve: Service and Repair Removal REMOVAL 1. Remove electrical connector (6) from Fuel Control Actuator (FCA). 2. Remove FCA mounting screws (1). 3. Twist and pull FCA to remove from injection pump. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Service and Repair > Removal > Page 7121 Fuel Inlet Metering Valve: Service and Repair Installation INSTALLATION 1. Lubricate new Fuel Control Actuator (FCA) O-ring with clean oil before installation. 2. Turn FCA in a clockwise direction while pressing it into machined bore on rear of fuel injection pump. Be sure FCA flange is flush with the mounting surface on fuel injection pump. 3. Install FCA mounting screws (1) by hand. 4. Tighten FCA mounting screws (1) to 7 Nm (62 in. lbs). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Diesel Fuel System - Fuel/Filtering Requirements Fuel: Technical Service Bulletins Diesel Fuel System - Fuel/Filtering Requirements NUMBER: 14-007-06 REV. A GROUP: Fuel DATE: September 02, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-007-06, DATED AUGUST 25, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL INFORMATION REGARDING FUELING OF EARLY BUILT 2007 RAM TRUCK CAB AND CHASSIS (DC) VEHICLES. SUBJECT: Fuel And Fuel Filtering Requirements For Cummins 5.9L And 6.7L Engines OVERVIEW: This bulletin involves a discussion regarding fuel system requirements. MODELS: 2006 - 2007 (DH/D1/DC) Ram Truck (Heavy Duty) NOTE: This bulletin applies to vehicles equipped with a 5.9L High Output or a 6.7L Cummins Turbo-Diesel Engine (sales codes ETH or ETJ respectively) that were built on or after March 07, 2006 (MDH 0307XX). DISCUSSION: Current Fuel Systems: - For the diesel engine system to operate at its peak performance a high level of fuel quality must be maintained. Emission control and fuel delivery systems have advanced significantly. Care must be taken to insure that the fuel that is delivered to the engine fuel injection system is of the highest quality possible and free of contaminants. - Significant components to fuel quality are: the initial quality of the fuel (as dispensed from the service station fuel pump or bulk storage), on-vehicle fuel storage, and the on-vehicle fuel filtering of the diesel fuel prior to the fuel injection process. - Refer to the Owners Manual for fuel and fuel system information. Proper Fuel And Fuel Quality: - Use good quality diesel fuel from a reputable supplier. It is recommended that purchase of diesel fuel should be made from a service station that is known to dispense a high volume of highway diesel fuel. - ** Ultra Low Sulfur Highway Diesel Fuel (15 ppm of sulfur or less and meeting ASTM D975 grade 5-15) is required for use in Dodge Ram Trucks equipped with a 6.7L diesel engine. ** - ** The 2007 Ram Truck Cab and Chassis (DC) vehicle is equipped with a 6.7L diesel engine. This vehicle is to use Ultra Low Sulfur Highway Diesel Fuel. Due to limited availability of Ultra Low Sulfur Highway Diesel Fuel, during the initial production of this vehicle, Low Sulfur Highway Diesel Fuel (500 ppm of sulfur or less) may be used ONLY until Ultra Low Sulfur Highway Diesel fuel becomes readily available and fuel pumps that dispense Ultra Low Sulfur Highway Diesel Fuel are required to be labelled as such. This is expected to occur around October 15, 2006. ** - ** Ultra Low Sulfur Highway Diesel Fuel (preferred) or Low Sulfur Highway Diesel Fuel (500 ppm of sulfur or less) are required for use in Dodge Ram Trucks equipped with a 5.9L diesel engine. ** - A maximum blend of 5% biodiesel (B5) is acceptable as long as the biodiesel mixture meets ASTM specification D-975, D-975 - grade 5-15, and ASTM D6751. A biodiesel fuel blend that is higher than 5% is not acceptable without additional fuel processing because these higher percentage biodiesel blends contain excess amounts of moisture which exceed the water stripping capability of the on-engine final fuel filter. Should a higher percentage biodiesel fuels be used an auxiliary water stripping filter will be required. - A maximum blend of 20% biodiesel (B20) can be used by government, military, and commercial fleets who equip their vehicle(s) with an optional water separator, and adhere to the guidelines in the Department of Defense specification A-A-59693 (in addition to: ASTM specification D-975, D-975 - grade 5-15 and ASTM D6751) - Off-highway diesel fuel (i.e. farm or marine use diesel fuel) that does not meet Ultra Low Sulfur Highway or Low Sulfur Highway fuel specifications (as listed above) is NOT acceptable. Unknown sulfur and water content and unknown cetane number may adversely affect the performance of the Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Diesel Fuel System - Fuel/Filtering Requirements > Page 7126 engine and fuel injection system. - Fuel conditioners (additives) are not recommended and should not be required if you buy good quality fuel and follow cold weather advice supplied in the Owners Manual. Proper Bulk (Off-Vehicle) Fuel Storage: - Proper maintenance of stored fuel is essential. Diesel fuel is seldom entirely free of moisture. Fuel contaminated with moisture may develop a bacteria or "slime" that may restrict or block fuel filters and lines. - As diesel fuel is lighter than water, drain condensation no less than monthly from the diesel fuel supply/storage tanks. - Change the storage tank in-line filter regularly. This filter acts as the last filter prior to the diesel fuel entering the vehicle diesel fuel tank. Good quality diesel fuel is mandatory. If the storage tank does not have an in-line filter, then a in-line filter should be added. Refer to the table on the following page for recommended in-line filter specifications. Proper On-vehicle Fuel Storage And Filtering: - Proper on-vehicle fuel storage that prevents fuel contamination is important. - The original (OEM) vehicle fuel tank module (fuel pickup) filter performs a primary filtering of the on-vehicle diesel fuel as the fuel leaves the fuel tank and enters the fuel lines. - On-vehicle auxiliary diesel fuel tanks are often added by the vehicle owner to extend vehicle driving range. Auxiliary fuel tank systems must protect the quality of the diesel fuel just as well as the originally equipped (OEM) fuel tank that came with the vehicle when it was new. - On-vehicle auxiliary diesel fuel storage tanks must have a primary fuel filter to prevent contamination and moisture accumulation. Refer to the table on the following page for recommended filter specifications. - The prevention of moisture in the fuel system, the prevention of fuel stagnation, and the use of a primary fuel filter should all be considered in the purchase, installation, and maintenance of any auxiliary on-vehicle diesel fuel tank. Proper On-vehicle Final Fuel Filtering: - The large fuel filter mounted at the engine is the final fuel filter, water separator, fuel heater, and water drain. This filter is the final 'line of defense" when maintaining a high level of fuel quality. If the diesel fuel is contaminated or contains moisture, the engine mounted fuel filter system is the last chance to affect possible correction. - The quality of the fuel, its prior storage, and fuel handling prior to the final filter all have a significant impact on the amount of contamination and moisture entering the final fuel filter. - It is important to drain accumulated moisture/water at least monthly from the final fuel filter. Do not wait until the 'Water In Fuel" indicator illuminates before performing this maintenance. - Maintenance on the final fuel filter / water separator is important. Follow the maintenance schedule per the Owners Manual. Replace the filter more frequently if highly contaminated or high moisture content fuel is encountered. - On a 5.9L engine, if the final fuel filter is replaced due to a high moisture content diesel fuel, verify that the water sensor probes in the final filter have been cleaned. Excessive moisture may contaminate the sensor sensing probes. The 6.7L engine includes a new water-in-fuel sensor with the new final fuel filter element. - The final fuel / water separator filter must meet or exceed OEM specifications. Some aftermarket filters may not meet OEM specifications. - The final fuel I water separator filter must meet or exceed the filtration specifications listed in the table shown. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Diesel Fuel System - Fuel/Filtering Requirements > Page 7127 - Final fuel / water separator filters that meet the above specifications are approved for use on Cummins 5.9L and 6.7L diesel engines. - The use of non-approved fuel filters will result in engine performance deterioration, and/or possible progressive damage to the engine from foreign particle ingestion, and/or fuel system component corrosion. - It is recommended that customers use the MOPAR approved or Cummins Equivalent fuel filters to protect the engine from debris and water contamination. - The following final fuel / water separator filters are known to meet or exceed the specifications listed in the table above. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Diesel Fuel System - Fuel/Filtering Requirements > Page 7128 Fuel: Technical Service Bulletins Diesel Fuel System - Low Sulfur Fuel Usage NUMBER: 14-005-06 GROUP: Fuel DATE: July 27, 2006 SUBJECT: 5.9L And 6.7L Cummins Diesel Engines - Correct Low And Ultra-Low Sulfur Highway Diesel Fuel Use OVERVIEW: This bulletin involves a discussion regarding the correct diesel fuel to use for either the 5.9L or the 6.7L Cummins diesel engine. MODELS: 2007 (DHID1IDC) Ram Truck NOTE: This bulletin applies to vehicles equipped with a 5.9L or a 6.7L turbo-diesel engine (sales code ETH and ETJ respectively). DISCUSSION: 2007 M.Y. Dodge Ram trucks equipped with a 6.7L Cummins Turbo-Diesel engine are required by Federal law to be fueled with Ultra-Low Sulfur Diesel fuel. 2007 M.Y. Dodge Ram trucks equipped with a 5.9L Cummins Turbo-Diesel engine are allowed by Federal law to be fueled with Low Sulfur Diesel fuel, and are encouraged to fuel with Ultra-Low Sulfur Diesel fuel. As of June 1, 2006, a new United States Environmental Protection Agency (EPA) regulation required at least 80% of the United States diesel fuel production to be Ultra-Low Sulfur Highway Diesel fuel. Ultra-Low Sulfur Highway Diesel fuel has a sulfur content of 15 part per million (ppm). The new Ultra-Low Sulfur Highway Diesel fuel enables vehicles equipped with the advanced emissions control devices to achieve more stringent U.S. EPA vehicle emissions standards. By October 15, 2006, retail fuel stations that carry and dispense Ultra-Low Sulfur Highway Diesel fuel must label their fuel pumps with a Ultra-Low Sulfur Highway Diesel Fuel label (Fig. 1), and must meet the 15 ppm sulfur maximum requirement. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Diesel Fuel System - Fuel/Filtering Requirements > Page 7129 Federal law requires that the 2007 M.Y. Dodge Ram truck equipped with the 6.7L Cummins Turbo-Diesel engine must be fueled with Ultra-Low Sulfur Highway Diesel fuel, and prohibits the use of Low Sulfur Highway Diesel fuel to avoid damage to the emissions control systems. DaimlerChrysler's warranty does not cover the costs of repairing damage caused by the use of fuels other than those recommended in the owners manual. Effective June 1, 2006, EPA requires retail fuel stations that carry and dispense Low Sulfur Highway Diesel to label low sulfur fuel pumps with a Low Sulfur Highway Diesel Fuel label (Fig. 2). Low Sulfur Highway Diesel fuel may have a maximum sulfur content of 500 ppm (vs. 15 ppm). The label warns that Low Sulfur Highway Diesel fuel is prohibited from use in 2007 M.Y. and later diesel equipped vehicles. The U.S. EPA recognizes that some 2007 M.Y. diesel equipped vehicles are capable of operating on either Ultra-Low Sulfur Highway Diesel fuel or on Low Sulfur Highway Diesel fuel, as in the case of a 2007 M.Y. Dodge Ram Truck that is equipped with a 5.9L Cummins Turbo-Diesel engine. EPA has posted information to clarify the message on the following website: www.clean-diesel.org. To improve our customer's experience it is important to communicate the following: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Diesel Fuel System - Fuel/Filtering Requirements > Page 7130 A. The 2007 M.Y. Dodge Ram trucks equipped with a 5.9L Cummins Turbo-Diesel engine are encouraged to use Ultra-Low Sulfur Highway Diesel fuel, but have the flexibility to use either the Ultra-Low Sulfur Highway Diesel fuel or the Low Sulfur Highway Diesel fuel without the risk of penalty or damage to their emissions control system (Fig. 3). B. The 2007 M.Y. Dodge Ram trucks equipped with a 6.7L Cummins Turbo-Diesel engine are required by Federal law to fuel their vehicles with Ultra-Low Sulfur Highway Diesel fuel (Fig. 4). POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit Fuel Filter: Technical Service Bulletins Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit NUMBER: 14-004-11 GROUP: Fuel System DATE: April 01, 2011 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-002-10, DATED FEBRUARY 11, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE NEW PARTS. SUBJECT: Heavy Duty Filtration MOPAR Retrofit or Add On Parts Available MODELS: 2003 - 2009 (D1/DH/DR) Ram Truck (2500/3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH/DR vehicles equipped with a 5.9L Cummins engine built from 2003 model year (sales codes ETH, ETC) and DC/DH/D1/vehicles equipped with a 6.7L Cummins engine built from 2007 model year (sales code ETJ). DISCUSSION: Several fuel system add-on or retrofit parts are available to enhance the filtering capability for customers exposing their vehicles to extremely dirty conditions. Description of parts available for Cummins diesel equipped vehicles are listed below: ^ **Severe duty, frame mounted fuel filter** (application for 2004.5 - 2009 Pickup & 2007 - 2010 Cab Chassis DC). ^ 6.7L up-graded (5 & 10 micron filter-in-filter) fuel filter to retrofit earlier models (shell and element). ^ 6.7L Element only, fuel filter. ^ 5.9L & 6.7L Add-on or up-graded fuel tank vent hose kit with vent cap. ^ Filter for fuel tank vent hose, (replaces vent cap). ^ 5.9L up-graded air filter. This filter is similar in design to the current 6.7L air filter. NOTE: Do not sell p/n 05183410AA fuel filter for (bottom load style) 6.7L engines. Use 68061633AA shell and filter. NOTE: The maintenance intervals for the fuel filter(s) is 15,000 miles, 400 engine hours or 12 Months, (whichever occurs first) or more often as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 7135 PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 7136 Fuel Filter: Technical Service Bulletins Fuel System - Severe Duty Filtration Kit Availability NUMBER: 14-001-09 GROUP: Fuel DATE: January 24, 2009 SUBJECT: Severe Duty Fuel Filtration Mopar Add On Kit Available MODELS: 2005 - 2009 (D1/DH) Ram Truck (2500/3500 Pick Up) 2007 - 2009 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH vehicles equipped with a 5.9L Cummins engine built from 2005 model year and D1/DH/DC vehicles equipped with a 6.7L Cummins engine built from 2007 model year. DISCUSSION: A frame mounted supplemental filter kit is now available for the vehicles listed above. This kit includes complete instructions (K6855569AC) with all necessary components and wiring to upgrade fuel filtering to a severe duty rating. NOTE: The maintenance intervals for the fuel filters (on engine filter and added chassis mounted severe duty fuel filtration kit filter) are 15,000 miles. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 7137 Fuel Filter: Technical Service Bulletins Diesel Fuel System - Fuel/Filtering Requirements NUMBER: 14-007-06 REV. A GROUP: Fuel DATE: September 02, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-007-06, DATED AUGUST 25, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL INFORMATION REGARDING FUELING OF EARLY BUILT 2007 RAM TRUCK CAB AND CHASSIS (DC) VEHICLES. SUBJECT: Fuel And Fuel Filtering Requirements For Cummins 5.9L And 6.7L Engines OVERVIEW: This bulletin involves a discussion regarding fuel system requirements. MODELS: 2006 - 2007 (DH/D1/DC) Ram Truck (Heavy Duty) NOTE: This bulletin applies to vehicles equipped with a 5.9L High Output or a 6.7L Cummins Turbo-Diesel Engine (sales codes ETH or ETJ respectively) that were built on or after March 07, 2006 (MDH 0307XX). DISCUSSION: Current Fuel Systems: - For the diesel engine system to operate at its peak performance a high level of fuel quality must be maintained. Emission control and fuel delivery systems have advanced significantly. Care must be taken to insure that the fuel that is delivered to the engine fuel injection system is of the highest quality possible and free of contaminants. - Significant components to fuel quality are: the initial quality of the fuel (as dispensed from the service station fuel pump or bulk storage), on-vehicle fuel storage, and the on-vehicle fuel filtering of the diesel fuel prior to the fuel injection process. - Refer to the Owners Manual for fuel and fuel system information. Proper Fuel And Fuel Quality: - Use good quality diesel fuel from a reputable supplier. It is recommended that purchase of diesel fuel should be made from a service station that is known to dispense a high volume of highway diesel fuel. - ** Ultra Low Sulfur Highway Diesel Fuel (15 ppm of sulfur or less and meeting ASTM D975 grade 5-15) is required for use in Dodge Ram Trucks equipped with a 6.7L diesel engine. ** - ** The 2007 Ram Truck Cab and Chassis (DC) vehicle is equipped with a 6.7L diesel engine. This vehicle is to use Ultra Low Sulfur Highway Diesel Fuel. Due to limited availability of Ultra Low Sulfur Highway Diesel Fuel, during the initial production of this vehicle, Low Sulfur Highway Diesel Fuel (500 ppm of sulfur or less) may be used ONLY until Ultra Low Sulfur Highway Diesel fuel becomes readily available and fuel pumps that dispense Ultra Low Sulfur Highway Diesel Fuel are required to be labelled as such. This is expected to occur around October 15, 2006. ** - ** Ultra Low Sulfur Highway Diesel Fuel (preferred) or Low Sulfur Highway Diesel Fuel (500 ppm of sulfur or less) are required for use in Dodge Ram Trucks equipped with a 5.9L diesel engine. ** - A maximum blend of 5% biodiesel (B5) is acceptable as long as the biodiesel mixture meets ASTM specification D-975, D-975 - grade 5-15, and ASTM D6751. A biodiesel fuel blend that is higher than 5% is not acceptable without additional fuel processing because these higher percentage biodiesel blends contain excess amounts of moisture which exceed the water stripping capability of the on-engine final fuel filter. Should a higher percentage biodiesel fuels be used an auxiliary water stripping filter will be required. - A maximum blend of 20% biodiesel (B20) can be used by government, military, and commercial fleets who equip their vehicle(s) with an optional water separator, and adhere to the guidelines in the Department of Defense specification A-A-59693 (in addition to: ASTM specification D-975, D-975 - grade 5-15 and ASTM D6751) - Off-highway diesel fuel (i.e. farm or marine use diesel fuel) that does not meet Ultra Low Sulfur Highway or Low Sulfur Highway fuel specifications (as listed above) is NOT acceptable. Unknown sulfur and water content and unknown cetane number may adversely affect the performance of the Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 7138 engine and fuel injection system. - Fuel conditioners (additives) are not recommended and should not be required if you buy good quality fuel and follow cold weather advice supplied in the Owners Manual. Proper Bulk (Off-Vehicle) Fuel Storage: - Proper maintenance of stored fuel is essential. Diesel fuel is seldom entirely free of moisture. Fuel contaminated with moisture may develop a bacteria or "slime" that may restrict or block fuel filters and lines. - As diesel fuel is lighter than water, drain condensation no less than monthly from the diesel fuel supply/storage tanks. - Change the storage tank in-line filter regularly. This filter acts as the last filter prior to the diesel fuel entering the vehicle diesel fuel tank. Good quality diesel fuel is mandatory. If the storage tank does not have an in-line filter, then a in-line filter should be added. Refer to the table on the following page for recommended in-line filter specifications. Proper On-vehicle Fuel Storage And Filtering: - Proper on-vehicle fuel storage that prevents fuel contamination is important. - The original (OEM) vehicle fuel tank module (fuel pickup) filter performs a primary filtering of the on-vehicle diesel fuel as the fuel leaves the fuel tank and enters the fuel lines. - On-vehicle auxiliary diesel fuel tanks are often added by the vehicle owner to extend vehicle driving range. Auxiliary fuel tank systems must protect the quality of the diesel fuel just as well as the originally equipped (OEM) fuel tank that came with the vehicle when it was new. - On-vehicle auxiliary diesel fuel storage tanks must have a primary fuel filter to prevent contamination and moisture accumulation. Refer to the table on the following page for recommended filter specifications. - The prevention of moisture in the fuel system, the prevention of fuel stagnation, and the use of a primary fuel filter should all be considered in the purchase, installation, and maintenance of any auxiliary on-vehicle diesel fuel tank. Proper On-vehicle Final Fuel Filtering: - The large fuel filter mounted at the engine is the final fuel filter, water separator, fuel heater, and water drain. This filter is the final 'line of defense" when maintaining a high level of fuel quality. If the diesel fuel is contaminated or contains moisture, the engine mounted fuel filter system is the last chance to affect possible correction. - The quality of the fuel, its prior storage, and fuel handling prior to the final filter all have a significant impact on the amount of contamination and moisture entering the final fuel filter. - It is important to drain accumulated moisture/water at least monthly from the final fuel filter. Do not wait until the 'Water In Fuel" indicator illuminates before performing this maintenance. - Maintenance on the final fuel filter / water separator is important. Follow the maintenance schedule per the Owners Manual. Replace the filter more frequently if highly contaminated or high moisture content fuel is encountered. - On a 5.9L engine, if the final fuel filter is replaced due to a high moisture content diesel fuel, verify that the water sensor probes in the final filter have been cleaned. Excessive moisture may contaminate the sensor sensing probes. The 6.7L engine includes a new water-in-fuel sensor with the new final fuel filter element. - The final fuel / water separator filter must meet or exceed OEM specifications. Some aftermarket filters may not meet OEM specifications. - The final fuel I water separator filter must meet or exceed the filtration specifications listed in the table shown. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 7139 - Final fuel / water separator filters that meet the above specifications are approved for use on Cummins 5.9L and 6.7L diesel engines. - The use of non-approved fuel filters will result in engine performance deterioration, and/or possible progressive damage to the engine from foreign particle ingestion, and/or fuel system component corrosion. - It is recommended that customers use the MOPAR approved or Cummins Equivalent fuel filters to protect the engine from debris and water contamination. - The following final fuel / water separator filters are known to meet or exceed the specifications listed in the table above. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Description and Operation > Description Fuel Filter: Description and Operation Description DESCRIPTION The fuel filter/water separator assembly is located on left side of engine above the starter motor. The assembly also includes the fuel heater, water drain valve, Water-In-Fuel (WIF) sensor and a quick-connect fittings attached at the side of the fuel filter canister. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Description and Operation > Description > Page 7142 Fuel Filter: Description and Operation Operation OPERATION The fuel filter/water separator protects the fuel injection pump by removing water and contaminants from the fuel. The construction of the filter/separator allows fuel to pass through it, but helps prevent moisture (water) from doing so. Moisture collects at the bottom of the filter. Refer to the maintenance schedules for the recommended fuel filter replacement intervals. For draining of water from canister, refer to Fuel/Water Separator Removal. There is a screened quick-connect fitting that is attached at the side of the fuel filter canister. It provides additional filtering for the high pressure fuel system components. A Water-In-Fuel (WIF) sensor is attached to the bottom of fuel filter element. The fuel heater is installed into the side of the filter/separator housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Removal Fuel Filter: Service and Repair Removal REMOVAL Refer to maintenance schedules for recommended fuel filter replacement intervals. Draining water from fuel filter canister: The housing drain valve (3) serves two purposes. One is to partially drain the filter housing of excess water. The other is to partially drain the housing for fuel filter or heater element replacement. The filter housing (1) should be partially drained whenever the water-in-fuel warning lamp remains illuminated. (Note that lamp will be illuminated for approximately two seconds when ignition key is initially placed in ON position for a bulb check). 1. A drain hose (4) is located at the bottom of drain valve. Place drain pan under drain hose. 2. With engine not running, rotate drain valve (3) approximately two revolutions to open it. Leave open until all water and contaminants have been removed and clean fuel exits. Hand tighten drain valve after tightening. 3. If fuel heater element is being replaced, drain housing completely. Dispose of mixture in drain pan according to applicable regulations. 4. After draining operation, close and tighten drain valve (3). 5. Fuel Filter Replacement: a. Remove left front tire/wheel. b. Remove left front wheel splash shield. c. Clean all debris from around filter canister (1) and canister head. d. Disconnect WIF sensor electrical connector (5). e. Open drain valve (3) two complete revolutions. Drain approximately 1 cup of fuel into a waste canister. Dispose of fuel according to environmental regulations. f. Remove drain hose (4) from drain valve (3). g. Use an oil filter type wrench to loosen filter (1). Continue removing filter by hand. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Removal > Page 7145 6. After fuel filter removal, also check and clean secondary filter screen. Press button (2) on quick-connect fitting. Disconnect fitting (1) from fitting (3). Unscrew fitting (3) from canister head to expose screen. 7. Clean screen (5) and check condition of O-ring (6). 8. Water-In-Fuel (WIF) Sensor Replacement: The WIF sensor (2) is located on the bottom of the fuel filter housing. The WIF sensor is not a separately serviceable item. If diagnostics have led you to replace this sensor, then the whole fuel filter assembly (1) needs to be changed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Removal > Page 7146 9. Fuel Heater Element Replacement: The heater element (2) is located in the fuel filter housing (4). a. Drain fuel filter. See previous steps. b. Disconnect electrical connector (1). c. Remove two mounting screws (3). d. Remove fuel heater (2). 10. Check condition of fuel heater O-ring (2). 11. Drain Valve Replacement: The Drain Valve is located on the bottom of the fuel filter. This is not a separately serviceable item. If replacement is necessary, replace the entire filter/filter canister assembly. 12. Fuel Filter Head (Housing) Replacement: a. If equipped, remove transmission dipstick tube from filter housing. b. Remove all low-pressure fuel lines at filter housing c. Remove housing from cylinder head. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Removal > Page 7147 Fuel Filter: Service and Repair Installation INSTALLATION Refer to maintenance schedules for recommended fuel filter replacement intervals. 1. Fuel Filter: CAUTION: Do not pre-fill the fuel filter with fuel. Severe damage to fuel system and injection system components may result. a. The engine has a self-priming low-pressure fuel system. b. Lubricate new fuel filter O-ring with clean engine oil. c. Position new fuel filter/canister assembly (1) to housing. d. Rotate fuel filter/canister assembly (1) until it comes to a hard stop. e. Tighten the filter element an additional half-inch of rotation. f. Connect WIF sensor electrical connector (5). g. Attach drain hose (4) to drain valve (3). h. Install left front tire/wheel. i. Install left front wheel splash shield. 2. Clean screen (5). 3. Check condition of new O-ring (6) and lubricate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Removal > Page 7148 4. Install screen assembly into housing and tighten fitting (3) to 20 ft. lbs. (27 Nm). 5. Connect quick connect fuel supply line (1) to fitting (3). 6. Fuel Heater Element: a. Check condition of O-ring (2). b. Lubricate new element O-ring before installation. 7. Install fuel heater element (3) into fuel filter housing (4). 8. Install two fuel heater mounting screws (3) and tighten to 60 in lbs. (6.8 Nm). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Removal > Page 7149 9. Connect electrical connector (1). 10. Fuel Filter Head (Housing): a. Install fuel filter head to cylinder head. Tighten bolts to 32 Nm (24 ft. lbs.) torque. b. Replace sealing washers on banjo bolts and install all low-pressure fuel lines to filter housing. Tighten banjo bolts to 24 Nm (18 ft. lbs.) torque. Tighten quick-connect fitting to 27 Nm (20 ft. lbs.) torque. c. If equipped, install transmission dipstick tube to filter housing. Tighten bolt to 10 Nm (8 ft. lbs.) torque. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Heater-Fuel Fuel Heater: Locations Heater-Fuel Component ID: 139 Component : HEATER-FUEL Connector: Name : HEATER-FUEL Color : # of pins : 2 Qualifier : (DIESEL) A GROUND Z902 14BK A GROUND Z816 14BK B FUEL HEATER CONTROL OUTPUT A961 14RD Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Heater-Fuel > Page 7154 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Heater-Fuel > Page 7155 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Heater-Fuel > Page 7156 Fuel Heater: Locations Fuel Heater Element The heater element (2) is located in the fuel filter housing (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Page 7157 Fuel Heater: Diagrams Component ID: 139 Component : HEATER-FUEL Connector: Name : HEATER-FUEL Color : # of pins : 2 Qualifier : (DIESEL) A GROUND Z902 14BK A GROUND Z816 14BK B FUEL HEATER CONTROL OUTPUT A961 14RD Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Page 7158 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Page 7159 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Page 7160 Fuel Heater: Description and Operation OPERATION The fuel heater is used to prevent diesel fuel from waxing during cold weather operation. When the fuel temperature is below 45 ± 8° F (7° C), the temperature sensor allows current to flow to the heater element warming the fuel. When the fuel temperature is above 75 ± 8° F (24° C), the sensor stops current flow to the heater element. Battery voltage to operate the fuel heater element is supplied from the ignition switch and through a solid stated device in the TIPM. The fuel heater element and "solid state device in TIPM" are not computer controlled. The heater element operates on 12 volts, 300 watts at 0° F (-18° C). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Page 7161 Fuel Heater: Testing and Inspection FUEL HEATER The fuel heater is used to prevent diesel fuel from waxing during cold weather operation. NOTE: The fuel heater element, "solid state device in TIPM" is not controlled by the Engine Control Module (ECM). A malfunctioning fuel heater can cause a wax build-up in the fuel filter/water separator. Wax build-up in the filter/separator can cause engine starting problems and prevent the engine from revving up. It can also cause blue or white fog-like exhaust. If the heater is not operating in cold temperatures, the engine may not operate due to fuel waxing. The fuel heater assembly is located on the side of fuel filter housing and internal to the fuel filter housing. The heater assembly is equipped with a built-in fuel temperature sensor (thermostat) that senses fuel temperature. When fuel temperature drops below 45 ° ± 8° F (7° C), the sensor allows current to flow to built-in heater element to warm fuel. When fuel temperature rises above 75° ± 8° F (24° C), the sensor stops current flow to heater element (circuit is open). Voltage to operate fuel heater element is supplied from ignition switch, through "solid state device in TIPM", to fuel temperature sensor and on to fuel heater element. The heater element operates on 12 volts, 300 watts at 0° F (-18° C). As temperature increases, power requirements decrease. A minimum of 7 volts is required to operate the fuel heater. The resistance value of the heater element is less than 1 ohm (cold) and up to 1000 ohms warm. TESTING 1. Disconnect electrical connector (1) from heater element. Ambient temperature must be below the circuit close temperature. If necessary, induce this ambient temperature by placing ice packs on thermostat to produce an effective ambient temperature below circuit close temperature. Measure resistance across two pins. Operating range is 0.3 - 0.45 Ohms. 2. If resistance is out of range, replace heater element. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Page 7162 Fuel Heater: Service and Repair Fuel Heater Element Replacement: The heater element (2) is located in the fuel filter housing (4). a. Drain fuel filter. See previous steps. b. Disconnect electrical connector (1). c. Remove two mounting screws (3). d. Remove fuel heater (2). Check condition of fuel heater O-ring (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 Fuel Injector: Locations Injector-Fuel 1 Component ID: 145 Component : INJECTOR-FUEL 1 Connector: Name : INJECTOR-FUEL 1 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 1 K611 14BK 2 INJECTOR CONTROL NO. 1 K11 14BK Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7167 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7168 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7169 Connector: Name : INJECTOR-FUEL 1 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 1 K11 18BR/YL 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7170 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7171 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7172 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7173 Fuel Injector: Locations Injector-Fuel 2 Component ID: 146 Component : INJECTOR-FUEL 2 Connector: Name : INJECTOR-FUEL 2 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 2 K612 14BK 2 INJECTOR CONTROL NO. 2 K12 14BK Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7174 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7175 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7176 Connector: Name : INJECTOR-FUEL 2 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 2 K12 18BR/DB 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7177 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7178 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7179 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7180 Fuel Injector: Locations Injector-Fuel 3 Component ID: 147 Component : INJECTOR-FUEL 3 Connector: Name : INJECTOR-FUEL 3 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 3 K613 14BK 2 INJECTOR CONTROL NO. 3 K13 14BK Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7181 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7182 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7183 Connector: Name : INJECTOR-FUEL 3 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 3 K13 18BR/LB 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7184 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7185 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7186 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7187 Fuel Injector: Locations Injector-Fuel 4 Component ID: 148 Component : INJECTOR-FUEL 4 Connector: Name : INJECTOR-FUEL 4 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 4 K614 14BK 2 INJECTOR CONTROL NO. 4 K14 14BK Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7188 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7189 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7190 Connector: Name : INJECTOR-FUEL 4 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 4 K14 18BR/TN 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7191 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7192 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7193 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7194 Fuel Injector: Locations Injector-Fuel 1 Component ID: 145 Component : INJECTOR-FUEL 1 Connector: Name : INJECTOR-FUEL 1 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 1 K611 14BK 2 INJECTOR CONTROL NO. 1 K11 14BK Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7195 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7196 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7197 Connector: Name : INJECTOR-FUEL 1 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 1 K11 18BR/YL 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7198 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7199 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7200 Injector-Fuel 2 Component ID: 146 Component : INJECTOR-FUEL 2 Connector: Name : INJECTOR-FUEL 2 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7201 Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 2 K612 14BK 2 INJECTOR CONTROL NO. 2 K12 14BK Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7202 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7203 Connector: Name : INJECTOR-FUEL 2 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 2 K12 18BR/DB 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7204 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7205 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7206 Injector-Fuel 3 Component ID: 147 Component : INJECTOR-FUEL 3 Connector: Name : INJECTOR-FUEL 3 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7207 Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 3 K613 14BK 2 INJECTOR CONTROL NO. 3 K13 14BK Component Location - 8 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7208 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7209 Connector: Name : INJECTOR-FUEL 3 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 3 K13 18BR/LB 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7210 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7211 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7212 Injector-Fuel 4 Component ID: 148 Component : INJECTOR-FUEL 4 Connector: Name : INJECTOR-FUEL 4 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7213 Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 4 K614 14BK 2 INJECTOR CONTROL NO. 4 K14 14BK Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7214 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7215 Connector: Name : INJECTOR-FUEL 4 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 4 K14 18BR/TN 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7216 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7217 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7218 Injector-Fuel 5 Component ID: 149 Component : INJECTOR-FUEL 5 Connector: Name : INJECTOR-FUEL 5 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7219 Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 5 K638 14BK 2 INJECTOR CONTROL NO. 5 K38 14BK Component Location - 8 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7220 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7221 Connector: Name : INJECTOR-FUEL 5 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 5 K38 18BR/OR 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7222 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7223 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7224 Injector-Fuel 6 Component ID: 150 Component : INJECTOR-FUEL 6 Connector: Name : INJECTOR-FUEL 6 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7225 Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 6 K658 14BK 2 INJECTOR CONTROL NO. 6 K58 14BK Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7226 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7227 Connector: Name : INJECTOR-FUEL 6 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 6 K58 18BR/VT 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7228 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7229 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 7230 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 Fuel Injector: Diagrams Injector-Fuel 1 Component ID: 145 Component : INJECTOR-FUEL 1 Connector: Name : INJECTOR-FUEL 1 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 1 K611 14BK 2 INJECTOR CONTROL NO. 1 K11 14BK Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7233 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7234 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7235 Connector: Name : INJECTOR-FUEL 1 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 1 K11 18BR/YL 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7236 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7237 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7238 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7239 Fuel Injector: Diagrams Injector-Fuel 2 Component ID: 146 Component : INJECTOR-FUEL 2 Connector: Name : INJECTOR-FUEL 2 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 2 K612 14BK 2 INJECTOR CONTROL NO. 2 K12 14BK Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7240 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7241 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7242 Connector: Name : INJECTOR-FUEL 2 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 2 K12 18BR/DB 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7243 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7244 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7245 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7246 Fuel Injector: Diagrams Injector-Fuel 3 Component ID: 147 Component : INJECTOR-FUEL 3 Connector: Name : INJECTOR-FUEL 3 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 3 K613 14BK 2 INJECTOR CONTROL NO. 3 K13 14BK Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7247 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7248 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7249 Connector: Name : INJECTOR-FUEL 3 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 3 K13 18BR/LB 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7250 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7251 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7252 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7253 Fuel Injector: Diagrams Injector-Fuel 4 Component ID: 148 Component : INJECTOR-FUEL 4 Connector: Name : INJECTOR-FUEL 4 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 4 K614 14BK 2 INJECTOR CONTROL NO. 4 K14 14BK Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7254 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7255 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7256 Connector: Name : INJECTOR-FUEL 4 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 4 K14 18BR/TN 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7257 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7258 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7259 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7260 Fuel Injector: Diagrams Injector-Fuel 1 Component ID: 145 Component : INJECTOR-FUEL 1 Connector: Name : INJECTOR-FUEL 1 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 1 K611 14BK 2 INJECTOR CONTROL NO. 1 K11 14BK Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7261 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7262 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7263 Connector: Name : INJECTOR-FUEL 1 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 1 K11 18BR/YL 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7264 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7265 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7266 Injector-Fuel 2 Component ID: 146 Component : INJECTOR-FUEL 2 Connector: Name : INJECTOR-FUEL 2 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7267 Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 2 K612 14BK 2 INJECTOR CONTROL NO. 2 K12 14BK Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7268 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7269 Connector: Name : INJECTOR-FUEL 2 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 2 K12 18BR/DB 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7270 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7271 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7272 Injector-Fuel 3 Component ID: 147 Component : INJECTOR-FUEL 3 Connector: Name : INJECTOR-FUEL 3 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7273 Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 1 K227 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 3 K613 14BK 2 INJECTOR CONTROL NO. 3 K13 14BK Component Location - 8 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7274 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7275 Connector: Name : INJECTOR-FUEL 3 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 3 K13 18BR/LB 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7276 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7277 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7278 Injector-Fuel 4 Component ID: 148 Component : INJECTOR-FUEL 4 Connector: Name : INJECTOR-FUEL 4 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7279 Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 4 K614 14BK 2 INJECTOR CONTROL NO. 4 K14 14BK Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7280 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7281 Connector: Name : INJECTOR-FUEL 4 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 4 K14 18BR/TN 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7282 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7283 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7284 Injector-Fuel 5 Component ID: 149 Component : INJECTOR-FUEL 5 Connector: Name : INJECTOR-FUEL 5 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7285 Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 5 K638 14BK 2 INJECTOR CONTROL NO. 5 K38 14BK Component Location - 8 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7286 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7287 Connector: Name : INJECTOR-FUEL 5 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 5 K38 18BR/OR 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7288 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7289 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7290 Injector-Fuel 6 Component ID: 150 Component : INJECTOR-FUEL 6 Connector: Name : INJECTOR-FUEL 6 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7291 Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER-BANK 2 K229 14BK Pin Description Circuit 1 INJECTOR HIGH SIDE DRIVER NO. 6 K658 14BK 2 INJECTOR CONTROL NO. 6 K58 14BK Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7292 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7293 Connector: Name : INJECTOR-FUEL 6 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Description Circuit 1 INJECTOR CONTROL NO. 6 K58 18BR/VT 2 ASD CONTROL OUTPUT K342 16BR/WT Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7294 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7295 Component Location - 15 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 7296 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Description Fuel Injector: Description and Operation Description DESCRIPTION Six individual, solenoid actuated high-pressure fuel injectors are used (6). The injectors are vertically mounted into a bored hole in the top of the cylinder head. This bored hole is located between the intake/exhaust valves. High-pressure connectors (13), mounted into the side of the cylinder head, connect each fuel injector to each high-pressure fuel line (1). FUEL INJECTOR ID CORRECTION CODES: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Description > Page 7299 Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector (1) and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Engine Control Module (ECM) using a diagnostic scan tool. In addition, if a new ECM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new ECM. The valve cover and valve cover gasket will need to be removed in order to manually record the values from the original injectors. Contact cleaner or brake cleaner may be used to clean the fuel injector. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Description > Page 7300 Fuel Injector: Description and Operation Operation OPERATION High-pressure fuel is supplied from the injection pump, through a high-pressure fuel line, into a fuel rail, through high-pressure lines, through steel connectors and into the solenoid actuated fuel injector. The ECM actuates the solenoid causing the needle valve to rise and fuel flows through the spray holes in the nozzle tip into the combustion chamber. Each fuel injector is connected to the fuel rail by a high-pressure fuel line and a steel connector. This steel connector is positioned into the cylinder head and sealed with an O-ring. The connector is retained in the cylinder head by a nut (fitting) that is threaded into the cylinder head. The torquing force of this threaded nut (fitting) provides a sealing pressure between the fuel line connector and the fuel injector. Retaining nut torque is very critical. If the nut (fitting) is under torqued, the mating surfaces will not seal and a high-pressure fuel leak will result. If the fitting is over torqued, the connector and injector will deform and also cause a high-pressure fuel leak. This leak will be inside the cylinder head and will not be visible. The result will be a possible fuel injector miss-fire and low power, or a no-start condition. The fuel injectors use hole type nozzles. High-pressure flows into the side of the injector, the ECM activates the solenoid causing the injector needle to lift and fuel to be injected. The clearances in the nozzle bore are extremely small and any dirt or contaminants will cause the injector to stick. Because of this, it is very important to do a thorough cleaning of any lines before opening up any fuel system component. Always cover or cap any open fuel connections before a fuel system repair is performed. Each fuel injector connector tube contains an edge filter that is designed to break up small contaminants before entering the fuel injector. The edge filters are not a substitute for proper cleaning and covering of all fuel system components during repair. The bottom of each fuel injector is sealed to the cylinder head with a 1.5mm thick copper shim (gasket). The correct thickness shim must always be re-installed after removing an injector. Fuel pressure in the injector circuit decreases after injection. The injector needle valve is immediately closed and fuel flow into the combustion chamber is stopped. Exhaust gases are prevented from entering the injector nozzle by the needle valve. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Page 7301 Fuel Injector: Testing and Inspection *INJECTOR RETURN FLOW TEST 1. ENGINE RUNS NOTE: Review Warranty bulletin D-05-24. NOTE: Battery charger may be utilized if cranking speed is below 170 RPM's. Does the engine run? Yes - Go To 2 No - Go To 3 2. * INJECTOR RETURN FLOW TEST @ 1200 RPM AND 1400 BAR RAIL PRESSURE 1. Operate the engine until the coolant temperature is above 180° F. 2. Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing. 3. Install fuel system test fitting 9012 in place of the banjo connector. 4. Remove the vehicle fuel return line from the engine fuel drain tube. 5. Install a piece of fuel line onto the test fitting and into a fuel container or into the fuel tank. 6. Install one end of a test hose onto the fuel drain tube. Place the other end of the test hose into a graduated cylinder. 7. Start engine and allow to idle for 30 sec. This step allows the flows to stabilize. Gather appropriate measuring device to measure collected return fuel. 8. Using the scan tool, navigate to ECM view -> PCM Cummins -> More Options-> System Tests -> Fuel Pressure override test. Select Start, then press Next. 9. Press the Run button on the screen. As you press the Run button to start the overpressure test, please move the injector return hose from the bucket and insert into the appropriate measuring device. The engine speed will elevate rapidly to 1200 rpm and the rail pressure will increase to 20000 psi (1400 bar). 10. While the test is running, please record the FCA duty cycle % and actual rail pressure record the readings on the Cummins Diesel Diagnostic Worksheet located under e-files, service, Star center in dealerconnect. 11. Measure and Record the amount of fuel collected. 12. If the flow is less than 160 ml/30 secs, the test has successfully passed, and the condition has been fixed 13. If the flow is greater than 250 ml/30 seconds, refer to step 20. 14. If the flow is greater than 160 ml/30 secs after step 11, shut off the engine and remove all 6 high pressure fuel lines. Re-torque the high-pressure connector nut. Inspect for damage, repair/replace as necessary. Reinstall high pressure fuel lines. 15. Start the engine and perform steps 7 through 10. 16. Measure the amount of fuel in the graduated cylinder. 17. If the amount of fuel is greater than 160 ml/30 sec, shut off the engine and remove the #1 high pressure fuel line. Cap the #1 fuel port using tool 9011 on the fuel rail and repeat steps 7 through 10. 18. Measure the amount of fuel in the graduated cylinder. If the amount is less than 160 ml.30 sec, remove and replace the #1 injector and #1 High pressure connector. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Page 7302 19. If the amount of fuel is not less than 160-ml/30 secs, repeat steps 17-18 for cylinders 2-6. 20. If the amount of fuel is greater than 250 ml/30 secs it is recommended that all 6 injectors be replaced. 21. Install all high-pressure connectors, fuel injectors, and fuel injector supply lines. Repeat steps 1-12 to confirm repair. SPECIFICATION: Less than 160 ml/ 30 seconds total fuel returns flow Repair - Test Complete. 3. * INJECTOR RETURN FLOW TEST DURING ENGINE CRANKING @200 RPM WHEN THE VEHICLE WILL NOT START 1. Install 9012 fitting in standard location on back of fuel filter head to measure pump and injector return flows. 2. Install hoses to the test fitting and the injector return line and route them to a bucket or other container. Make sure test lines are straight and slope downward their entire length. This is to avoid trapping air/fuel in the lines while testing. 3. Unplug the injector harnesses at the valve cover, Unplug the connector to the FCA. 4. Crank the engine for least 10 seconds until fuel starts to flow out of the pump and injector return hoses. Turn Key off when finished. 5. Let all the fuel drain out of each line before continuing. 6. Place the injector return hose into an appropriate measuring device. 7. Crank the engine for 10 seconds. Go from Keyoff to Crank back to Keyoff. Do not leave the ignition on between tests. 8. Let all of the fuel drain out of the injector hose. 9. Record the amount of injector return for a 10 sec crank. 10. Flow should be less than 40 ml for 10 seconds of cranking 11. If the flow is greater than 40 ml after step 10, remove the #1 fuel injector supply line. Re-torque the high-pressure connector nut. Cap the #1 fuel port using tool 9011 on the fuel rail. 12. Crank the engine and perform steps 7 through 9. 13. Measure the amount of fuel in the graduated cylinder. 14. If the amount of fuel is less than 40 ml, remove the #1 high pressure connector and the #1 fuel injector. Inspect for damage, repair/replace as necessary. 15. If the amount of fuel is not less than 40 ml, repeat steps 12-14 for cylinders 2-6. 16. Install all high-pressure connectors, fuel injectors, and fuel injector supply lines. Repeat steps 1-12 to confirm repair. Repair - Note: DTC's will be set by this process. Remember to go in and clear all DTC's from all modules. Test complete. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Removal Fuel Injector: Service and Repair Removal REMOVAL FUEL INJECTOR ID CORRECTION CODES: Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector (1) and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Engine Control Module (ECM) using a diagnostic scan tool. In addition, if a new ECM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new ECM. The valve cover and valve cover gasket will need to be removed in order to manually record the values from the original injectors. Contact cleaner or brake cleaner may be used to clean the fuel injector. NOTE: If the fuel injectors are being removed such as for engine teardown or diagnostic purposes, be sure to mark each injector with its corresponding cylinder number. The fuel injectors MUST be reinstalled into the original (same) cylinder due to the fuel injector correction code. NOTE: Do not install new fuel injectors unless the alphanumeric codes have been recorded. CAUTION: Refer to Cleaning Fuel System Parts. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Removal > Page 7305 Six individual, solenoid actuated high-pressure fuel injectors (7) are used. The injectors are vertically mounted into a bored hole in the top of the cylinder head. This bored hole is located between the intake/exhaust valves. High-pressure connectors, mounted into the side of the cylinder head, connect each fuel injector to each high-pressure fuel line. 1. Disconnect both negative battery cables from both batteries. Cover and isolate ends of cables. 2. Remove vanity cover. 3. Remove breather assembly and tubes. 4. Remove valve cover. 5. Remove all 12 fuel injector wire harness nuts (1) securing integrated wiring harness to all 6 fuel injectors. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Removal > Page 7306 6. An integrated fuel injector wire harness / valve cover gasket (2) is used. After all 12 nuts (1) have been removed, remove this integrated gasket. Before removing gasket, disconnect engine wiring harness at both electrical connectors (3). 7. Remove necessary high pressure fuel line connecting the necessary fuel injector rail to high pressure connector. 8. A connector retainer (nut) is used on each connector tube (12). Remove this nut(s) by unthreading from cylinder head. These nuts (12) hold the fuel injector retainers (13) to the fuel injector. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Removal > Page 7307 9. Using special high-pressure connector removal tool #9015 (4) remove necessary high-pressure connector(s) from cylinder head. Tool #9015 threads onto connector tube. Use tool to pry connector tube(s) from cylinder head. 10. Remove 2 fuel injector hold-down clamp bolts (1) at each injector being removed. 11. Remove necessary exhaust rocker arm assembly(s). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Removal > Page 7308 12. USING TOOL #9010: a. Special Tool #9010 is equipped with 2 clamshell clamps, a sliding retainer sleeve to retain the clamshell clamps, a 2-piece mounting stud, and a pivoting handle. Do not attempt to remove the fuel injector with any other device. Damage to injector will occur. b. The rocker housing is bolted to the top of cylinder head. The mounting stud from tool #9010 was meant to temporarily replace a rocker housing mounting bolt. Remove the necessary rocker housing mounting bolt. These mounting bolts are located at the center of each of the 5 rocker housing support bridges. c. Install and tighten 2-piece mounting stud to rocker housing. If removing the No. 6 fuel injector, separate the 2-piece mounting stud. Install lower half of mounting stud to center of rocker housing bridge. Install upper half of mounting stud to lower half. d. Position tool handle to mounting stud and install handle nut. Leave handle nut loose to allow a pivoting action. e. Position lower part of clamshell halves to sides of fuel injector (wider shoulder to bottom). The upper part of clamshell halves should also be positioned into machined shoulder on the handles pivoting head. f. Slide the retainer sleeve over pivoting handle head to lock clamshell halves together. g. Be sure handle pivot nut is loose. h. Depress handle downward to remove fuel injector straight up from cylinder head bore. 13. Remove and discard injector sealing washer (2). This washer (2) should be located on tip of injector, or may have remained in the injector bore. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Removal > Page 7309 14. Measure sealing gasket (washer) (1). NOTE: If the fuel injectors are being removed such as for engine teardown or diagnostic purposes, be sure to mark each injector with its corresponding cylinder number. The fuel injectors MUST be reinstalled into the original (same) cylinder due to the fuel injector correction code. NOTE: Do not install new fuel injectors unless the alphanumeric codes have been recorded. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Removal > Page 7310 Fuel Injector: Service and Repair Installation INSTALLATION 1. Inspect fuel injector : a. Look for burrs on injector inlet. b. Check nozzle holes for hole erosion or plugging. c. Inspect end of nozzle for burrs or rough machine marks. d. Look for cracks at nozzle end. e. If any of these conditions occur, replace injector. 2. Record six-digit alphanumeric correction code located on the side of injector. 3. Inspect high-pressure fuel injector connector for : a. Damaged tip. b. Loose of missing alignment pin. c. Cut or missing O-ring. 4. Thoroughly clean fuel injector cylinder head bore. Blow out bore hole with compressed air. 5. The bottom of fuel injector is sealed to cylinder head bore with a copper sealing washer (shim) (1) of a certain thickness. A new shim (1) with correct thickness must always be re-installed after removing injector. Measure thickness of injector shim (1). Shim Thickness: 1.5 mm (0.060 inch) 6. Install new shim (1) (washer) to bottom of injector. Apply light coating of clean engine oil to washer. This will keep washer in place during installation. 7. Install new O-ring to fuel injector. Apply small amount of clean engine oil to O-ring and injector bore. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Removal > Page 7311 8. Install injector into cylinder head with male (high-pressure) connector port facing the intake manifold. Push down on fuel injector mounting flange to engage O-ring and seat injector. 9. Tightening Sequence: a. Install fuel injector holdown clamp (mounting flange) bolts. Be sure the clamp is perpendicular to the injector body. Do a preliminary tightening of these bolts to 5 Nm (44 in. lbs.) torque. This preliminary tightening insures the fuel injector is seated and centered. b. After tightening, relieve bolt torque, but leave both bolts threaded in place. c. Install high-pressure connector (13) and retaining nut (12). Do a preliminary tightening of nut (12) to 15 Nm (11 ft. lbs.) torque. d. Alternately tighten injector holdown bolts to 8 Nm (71 in. lbs.) torque. e. Do a final tightening of the high-pressure connector and retaining nut (12). Tighten to 50 Nm (37 ft. lbs.) torque. 10. Install integrated gasket 11. Connect injector solenoid wires and nuts to top of injectors. Tighten connector nuts to 1.25 Nm (11 in. lbs.) torque. Be very careful not to overtighten these nuts as damage to fuel injector will occur. 12. Install exhaust rocker arm assembly. 13. Set exhaust valve lash. 14. Install fuel connector tube nut at cylinder head and tighten to 50 Nm (37 ft. lbs.). Be sure to use a secondary back-up wrench on the connector nut (fitting) while torquing fuel line fitting. 15. Install valve cover. 16. Install breather assembly. FUEL INJECTOR ID CORRECTION CODES: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Removal > Page 7312 Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector (1) and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Engine Control Module (ECM) using a diagnostic scan tool. In addition, if a new ECM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new ECM. 1. Connect negative battery cables to both batteries. 2. Programming Fuel Injector Correction Code: - Turn ignition switch "ON". - Using a diagnostic scan tool, select ECU View> PCM > MISCELLANEOUS FUNCTIONS. - Select Injector Quantity Adjustments and click Start. - Choose appropriate cylinder number and click next. - Click on Show Keyboard. NOTE: A fault code will be set if incorrect serialization codes have been inputted. - Input six-digit Injector Correction Code and click enter. - Review code as it was typed, then click Next if correct, or edit if necessary. - Repeat the preceding steps for other cylinders if necessary. - Once all fuel injector correction codes are entered, cycle the ignition to complete. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations Fuel Pressure Regulator: Locations The fuel pressure limiting valve (1) is screwed into the front of the fuel rail (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 7316 Fuel Pressure Regulator: Description and Operation OPERATION Fuel pressure at the fuel rail is monitored by the fuel rail pressure sensor. If fuel pressure becomes excessive, the pressure limiting valve opens and vents excess fuel pressure vents through the fuel pressure limiting valve drain port. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service and Repair > Removal Fuel Pressure Regulator: Service and Repair Removal REMOVAL CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only. The fuel pressure limiting valve (1) is screwed into the front of the fuel rail (2). The fuel pressure limiting valve drain port is located on the side of the fuel rail next to the limiting valve. The drain port is not serviceable. 1. Thoroughly clean area at pressure limiting valve (1). 2. To gain access to the limiting valve, the intake connection/EGR valve assembly must be removed. Loosen clamp (5) securing EGR crossover tube (6) to EGR valve. Also loosen opposite end of EGR crossover tube. Remove clamp from intake connection. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service and Repair > Removal > Page 7319 3. Remove six bolts (1) securing intake connection (2). Lift the entire EGR valve/intake connection up and to the side to gain access to fuel pressure limiting valve. 4. Discard gasket (3). 5. Remove pressure limiting valve from fuel rail. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service and Repair > Removal > Page 7320 Fuel Pressure Regulator: Service and Repair Installation INSTALLATION 1. Be sure both end of manifold and limiting valve mounting area are clean. 2. Lubricate O-ring on limiting valve with fresh diesel oil. Also lubricate limiting valve threads with fresh diesel oil. 3. Install valve (1) and torque to 100 Nm (74 ft. lbs.). To prevent leaks, valve MUST be tightened to prescribed torque. 4. Install new intake connection gasket (3). 5. Position EGR valve/intake connection and install six bolts. Tighten bolts to 24 Nm (18 ft. lbs.). 6. Install new EGR crossover tube gasket. Tighten crossover tube clamps to 10 Nm (88 in. lbs.). 7. Using a diagnostic scan tool, reset vale life by using the "Reset Two-Stage Dump Valve Accumulator" function in the PCM portion of the diagnostic tool Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service and Repair > Removal > Page 7321 8. Start engine and check for leaks. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure Fuel Pressure Sensor/Switch: Locations Sensor-Fuel Rail Pressure Component ID: 404 Component : SENSOR-FUEL RAIL PRESSURE Connector: Name : SENSOR-FUEL RAIL PRESSURE Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL RAIL SENSOR RETURN K915 18BR/WT Pin Description Circuit 1 SENSOR GROUND K916 18BR/OR 2 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 3 5 VOLT SUPPLY F855 18PK/YL Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure > Page 7326 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure > Page 7327 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure > Page 7328 Fuel Pressure Sensor/Switch: Locations Sensor-Fuel Pressure The fuel pressure sensor (1) is mounted to the rear of the fuel rail (6). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 7329 Fuel Pressure Sensor/Switch: Diagrams Component ID: 404 Component : SENSOR-FUEL RAIL PRESSURE Connector: Name : SENSOR-FUEL RAIL PRESSURE Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL RAIL SENSOR RETURN K915 18BR/WT Pin Description Circuit 1 SENSOR GROUND K916 18BR/OR 2 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 3 5 VOLT SUPPLY F855 18PK/YL Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 7330 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 7331 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 7332 Fuel Pressure Sensor/Switch: Description and Operation OPERATION The fuel pressure sensor monitors actual high-pressure within the fuel rail. An output signal from this sensor (relating to fuel pressure) is sent to the Engine Control Module (ECM). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal Fuel Pressure Sensor/Switch: Service and Repair Removal REMOVAL The fuel pressure sensor (1) is mounted to the rear of the fuel rail (6). 1. Remove two bolts (3) and bracket (4) at rear of cylinder head. 2. Remove engine oil dipstick tube mounting bolts. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal > Page 7335 3. Disconnect electrical connector (2) at sensor. 4. Remove sensor (1) from fuel rail. 5. Inspect sensor sealing surface. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal > Page 7336 Fuel Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Inspect fuel pressure sensor sealing surface. 2. Lubricate sensor threads with clean diesel fuel. 3. Install sensor (1) into fuel rail. 4. To prevent leaks, sensor must be tightened to 70 Nm (52 ft. lbs.). 5. Connect electrical connector (2) to sensor. 6. Install rear engine lift bracket (4) and bolts (3). Tighten to 77 Nm (57 ft. lbs.). 7. Install engine oil dipstick tube mounting bolts. 8. Start engine and check for fuel leaks. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL PRESSURES Fuel Pump/Gear Pump (low pressure) ................................................................................................................................ 551.5 - 1241 KPA (80 - 180 psi) Injection Pump ..................................................................................................................................... ............................ 200 - 1800 bar (2900 - 26107 psi) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test Fuel Pressure: Testing and Inspection Fuel Pump Return Flow Test *FUEL PUMP RETURN FLOW TEST 1. FUEL PUMP RETURN FLOW TEST Using the scan tool, idle the engine and measure the rail pressure and determine if the rail pressure is excessive (above 185,00 kpa/26,831 psi). If it is, troubleshoot for excessive rail pressure first. Remove the banjo bolt from the pressure-limiting valve on the fuel rail. Install fuel system test fitting 9013 into the pressure-limiting valve. Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose into a container Perform the tests listed below to determine if the pressure-limiting valve is leaking. a. Operate the engine at idle and watch for fuel flow into the fuel container. b. Operate the engine at idle and actuate the high pressure safety valve test with the scan tool. Watch for fuel flow into the fuel container. If fuel flows into the fuel container, replace the pressure-limiting valve. If fuel does not leak from the pressure-limiting valve, the test is complete. NOTE: Do not drive the vehicle with any portion of this test kit installed Operate the engine until the engine is at operating temperature. Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing Install fuel system test fitting 9012 in place of the banjo connector. Install a piece of fuel line onto the test fitting and put the open end into the graduated cylinder . Start the engine and let it idle for one minute. Measure the amount of fuel in the graduated cylinder. If the flow is less than 1000ml/minute at idle, the test has successfully passed. If the flow is greater than 1000ml/minute at idle, replace the fuel injection pump. Retest to confirm repair. View Repair Repair - Test Complete. - Perform POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 7343 Fuel Pressure: Testing and Inspection High Pressure Fuel Pump Performance Test *HIGH PRESSURE FUEL PUMP PERFORMANCE TEST If the engine will run do the following: 1. Monitor rail pressure with scan tool while the engine is at idle. 2. Compare the fuel pressure set point with the actual fuel pressure reading. 3. If actual fuel pressure reading fluctuates more than ± 500 psi from the set point, then replace the Fuel Control Actuator (FCA). NOTE: After the actuator is removed, check for debris or corrosion on the FCA. If debris or corrosion is found, replace the entire Fuel Injection Pump. 4. Turn off engine. 5. Disconnect the FCA harness 6. Disconnect high pressure fuel line from fuel rail and route the high pressure fuel line into a graduated cylinder. 7. Crank the engine until fuel exits this line. This will not be high pressure fuel. 8. Crank the engine for three (3) 10 second intervals (Note: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter). Fuel flow specification s based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL If the engine is a no start do the following: 1. Remove fuel pump to rail high pressure fuel line. 2. Inspect the fuel pump outlet port for rust, debris, or other signs of contamination. 3. Replace pump if any contamination is found. Check for source of water in fuel or debris in fuel to prevent future complaints. If no contamination is found continue to step 4. 4. Disconnect the Fuel Control Actuator (FCA). 5. Disconnect the high pressure fuel line from the fuel rail and route the high pressure fuel line to a graduated cylinder. 6. Crank the engine until fuel exits this line. This will not be high pressure fuel. 7. Crank the engine for three (3) 10 seconds intervals. NOTE: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter. Fuel flow specification's based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 7344 Fuel Pressure: Testing and Inspection In-Tank Fuel Lift Pump Flow/Diagnostic Test Procedure *IN-TANK FUEL LIFT PUMP FLOW/DIAGNOSTIC TEST PROCEDURE 1. Using the Scan tool, check for DTCs. Troubleshoot any active DTCs before performing this test. 2. Disconnect the wiring harness from the lift pump at the fuel tank module connector and inspect the pins for damage. Fix or replace any damaged component. 3. Connect a voltmeter between the fuel lift pump supply and return pins at the fuel tank module connector. 4. Turn the ignition to the on position. Use the Scan tool to actuate the fuel lift pump, record the voltage on the voltmeter. 5. If the voltage is greater than 11.5 volts, go to step 14. If the voltage is less than 11.5 volts, go to step 6 6. Using a voltmeter, measure the battery voltage to determine that the voltage is greater than 11.5 volts. If the voltage is greater than 11.5 volts, go to step 7. If the voltage is not greater than 11.5 volts, troubleshoot for low battery voltage. 7. Remove the fuel lift pump relay from the PDC. Use a voltmeter to measure the voltage at the fuel lift pump relay voltage supply pin in the PDC. If the voltage is greater than 11.5 volts, go to step 8. If the voltage is not greater than 11.5 volts, fix or replace the harness. 8. Remove the fuel lift pump relay from the PDC. Install a spare relay in place of the fuel lift pump relay. Using the Scan tool, actuate the fuel lift pump. Use a voltmeter to measure the voltage between the fuel lift pump supply and return pins at the fuel tank module connector while the fuel lift pump is actuated. If the voltage is greater than 11.5 volts, replace the fuel lift pump relay. If the voltage is not greater than 11.5 volts, go to step 9. 9. Disconnect the wiring harness from the fuel tank module. Remove the lift pump relay from the PDC. Using an Ohmmeter, measure the resistance of the fuel lift pump power supply wire between the PDC relay output pin and the fuel tank module connector. If the resistance is less than 10 ohms, go to step 10. If it is greater than 10 ohms, fix or replace the harness. 10. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using a voltmeter, measure the voltage between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the voltage is less than 1 volt, go to step 11. If the voltage is greater than 1 volt, fix or replace the harness. 11. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using an ohmmeter, measure the resistance between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the resistance is less than 10 ohms, fix or replace the harness. If the resistance is greater than 10 ohms, go to step 12. 12. Disconnect the wiring harness from the fuel tank module. Using an Ohmmeter, measure the resistance of the fuel lift pump ground wire between the fuel tank module connector and battery negative. If the resistance is less than 10 ohms, go to step 13. If the resistance is greater than 10 ohms, fix or replace the harness. 13. Disconnect the wiring harness from the fuel tank module. Using a voltmeter, measure the voltage between the fuel lift pump ground wire and battery negative. If the voltage is less than 1 volt, go to step 14. If the voltage is greater than 1 volt, fix or replace the harness. 14. Reconnect the lift pump connector. FLOW TEST. 1. Remove the fuel pump supply banjo fitting from the fuel injection pump. 2. Install fuel system test fitting 9863 onto the end of the quick connect line going to the fuel injection pump. 3. Connect one end of a section of fuel hose to the test fitting. 4. Put the other end of the fuel hose into an empty fuel container. 5. Use the scan tool to actuate the fuel lift pump. 6. While the lift pump is running, move the fuel hose from the fuel canister into a 1000ml graduated cylinder for 10 seconds. 7. Read and record the amount of fuel in the graduated cylinder after 10 seconds. 8. If you have more than 570ml in the graduated cylinder after 10 seconds, the test has successfully passed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 7345 9. If you have less than 570ml of fuel in the graduated cylinder, inspect the fuel supply line from the fuel tank to the fuel filter housing and the fuel supply line between the fuel filter housing and the high pressure fuel pump for signs of damage, replace as necessary. If no damage is found, replace the fuel filter and retest. 10.Verify the Screened Banjo Bolt at the outlet of the fuel filter is free of debris. If debris is found, rinse screen with water, blow dry and reinstall. Retest vehicle. If flow meets specification then trace back the source of debris, if flow is still below spec repair damaged component. 11. If reading is still less than 570ml in 10 seconds, remove the fuel tank and fuel tank module. Inspect for damage and/or debris in and around the fuel tank module. If module is damaged, replace and retest. 12. If the module is not damaged, replace the fuel lift pump and retest to confirm fix. Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 7349 8w-30-17 Connector C1 pin 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7352 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7353 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7354 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7355 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7356 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7357 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7358 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7359 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7360 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7361 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7362 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7363 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7364 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7365 Fuel Pump Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7366 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7367 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7368 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7369 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7370 Fuel Pump Relay: Connector Views Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 7371 Fuel Pump Relay: Description and Operation The fuel transfer pump (fuel lift pump) is part of the fuel pump module. The fuel pump module is located in the fuel tank. The 12-volt electric pump is operated and controlled by the Engine Control Module (ECM). The ECM controls a relay in the intelligent Power Module (IPM) for transfer pump operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation Fuel Rail: Description and Operation OPERATION The fuel rail is used as a distribution device to supply high-pressure fuel to the high-pressure fuel lines. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Removal Fuel Rail: Service and Repair Removal REMOVAL CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only. 1. Disconnect both negative battery cables at both batteries. Isolate ends of both cables. 2. Disconnect electrical connector at fuel pressure sensor (2). 3. Disconnect electrical connector at MAP sensor (3). 4. Disconnect necessary wiring harness retention clips from intake manifold. 5. Disconnect cables for intake air heater. 6. Remove fuel line (8). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Removal > Page 7377 7. Loosen fittings (9). CAUTION: WHEN LOOSENING OR TIGHTENING HIGH-PRESSURE LINE FITTINGS (11) ATTACHED TO A SEPARATE FITTING (12), USE A BACK-UP WRENCH ON FITTING (12). DO NOT ALLOW FITTING (12) TO ROTATE. DAMAGE TO BOTH FUEL LINE AND FITTING WILL RESULT. 8. Loosen fittings (11) and remove all fuel lines (1). Note and mark position of each fuel line while removing. 9. Remove fuel line connecting injection pump to fuel rail. 10. Remove fuel injection rail mounting bolts (7). 11. Remove rail (6) from top of intake manifold. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Removal > Page 7378 Fuel Rail: Service and Repair Installation INSTALLATION 1. Clean any dirt/debris from top of intake manifold and bottom of fuel rail. 2. Position fuel rail to top of manifold and install rail mounting bolts (7). Torque bolts to 24 Nm (18 ft. lbs.). CAUTION: WHEN LOOSENING OR TIGHTENING HIGH-PRESSURE LINE FITTINGS (11) ATTACHED TO A SEPARATE FITTING (12), USE A BACK-UP WRENCH ON FITTING (12). DO NOT ALLOW FITTING (12) TO ROTATE. DAMAGE TO BOTH FUEL LINE AND FITTING WILL RESULT. 3. Install all high-pressure lines to rail. Torque fittings to 30 Nm (22 ft. lbs.). 4. Reposition wiring harness to intake elbow and install nut. 5. Install two new sealing washers to fuel limiting valve banjo bolt. Torque to 24 Nm (18 ft. lbs.). 6. Connect electrical connector to fuel pressure sensor (2). 7. Connect electrical connector to MAP sensor (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Removal > Page 7379 8. Install air intake heater cables. 9. Connect battery cables to both batteries. 10. Start engine and check for leaks. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation > Description Fuel Return Line: Description and Operation Description DESCRIPTION Low-Pressure Lines Are: - the fuel supply line from fuel tank to fuel filter housing. - the fuel return line back to fuel tank. - the fuel drain (manifold) line at rear of cylinder head. - the fuel supply line from fuel filter to fuel injection pump. - the fuel injection pump return line. High-Pressure Lines Are: - the fuel line from fuel injection pump to fuel rail. - the six fuel lines from fuel rail up to injector connector tubes WARNING: High-pressure fuel lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. This may be as high as 180,000 kpa (26,107 psi). Use extreme caution when inspecting for high-pressure fuel leaks. Inspect for high-pressure fuel leaks with a sheet of cardboard. High fuel injection pressure can cause personal injury if contact is made with the skin. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation > Description > Page 7384 Fuel Return Line: Description and Operation Operation OPERATION High-Pressure Lines CAUTION: The high-pressure fuel lines must be held securely in the brace. The lines cannot contact each other or other components. Do not attempt to weld high-pressure fuel lines or to repair lines that are damaged. If lines are ever kinked or bent, they must be replaced. Use only the recommended lines when replacement of high-pressure fuel line is necessary. High-pressure fuel lines deliver fuel (under pressure) of up to approximately 180,000 kPa (26,107 PSI) from the injection pump to the fuel injectors. The lines expand and contract from the high-pressure fuel pulses generated during the injection process. All high-pressure fuel lines are of the same length and inside diameter. Correct high-pressure fuel line usage and installation is critical to smooth engine operation. WARNING: Use extreme caution when inspecting for high-pressure fuel leaks. Inspect for high-pressure fuel leaks with a sheet of cardboard. High fuel injection pressure can cause personal injury if contact is made with the skin. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Removal Fuel Return Line: Service and Repair Removal REMOVAL CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only. If removing fuel line at either No. 1 or No. 2 cylinder, the air inlet housing/EGR valve assembly must first be removed from the top of the intake manifold. 1. Disconnect both negative battery cables from both batteries. Cover and isolate ends of cables. 2. Thoroughly clean fuel lines at both ends. CAUTION: When loosening or tightening high-pressure lines attached to a separate fitting (11), use a back-up wrench on fitting (12). Do not allow fittings (12) to rotate. Damage to both fuel line and fitting will result. 3. If removing fuel line at # 6 cylinder, a bracket (4) is located above fuel line connection at cylinder head. Two bolts (3) secure this bracket to rear of cylinder head. The upper bolt hole is slotted. Loosen (but do not remove) these two bracket bolts. Tilt bracket down to gain access to # 6 fuel line connection. 4. If removing fuel line at either #1 or #2 cylinder, the air inlet housing/EGR assembly must first be removed from top of intake manifold. 5. Place shop towels around fuel lines at fuel rail and injectors. If possible, do not allow fuel to drip down side of engine. 6. Carefully remove each fuel line from engine. Note position of each while removing. Do not bend lines while removing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Removal > Page 7387 Fuel Return Line: Service and Repair Installation INSTALLATION All high-pressure fuel lines are of the same length and inside diameter. Correct high-pressure fuel line usage and installation is critical to smooth engine operation. CAUTION: Anytime a high-pressure line is removed from the engine, its fuel connector nut (12) at the cylinder head must first be retorqued. 1. Tighten nuts (12) at high pressure injector connector nut at the cylinder head. Torque nut to 50 Nm (37 ft. lbs.). 2. Position proper fuel line to proper injector on engine. Tighten fittings hand tight at both ends of line. 3. Tighten fuel line at cylinder head. Torque nut to 40 Nm (30 ft. lbs.). 4. Tighten fuel line nuts at fuel rail to 40 Nm (30 ft. lbs.). 5. If fuel line at No. 6 cylinder has been replaced, tilt metal bracket (4) upward and tighten two bolts (3) at rear of cylinder head. Tighten to 43 Nm (32 ft. lbs.). 6. If necessary, install EGR valve/air intake manifold assembly. 7. Connect both negative battery cables to both batteries. 8. Prime fuel system. 9. Check lines/fittings for leaks. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Description Fuel Supply Line: Description and Operation Description DESCRIPTION Low-Pressure Lines Are: - the fuel supply line from fuel tank to fuel filter housing. - the fuel return line back to fuel tank. - the fuel drain (manifold) line at rear of cylinder head. - the fuel supply line from fuel filter to fuel injection pump. - the fuel injection pump return line. High-Pressure Lines Are: - the fuel line from fuel injection pump to fuel rail. - the six fuel lines from fuel rail up to injector connector tubes WARNING: High-pressure fuel lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. This may be as high as 180,000 kpa (26,107 psi). Use extreme caution when inspecting for high-pressure fuel leaks. Inspect for high-pressure fuel leaks with a sheet of cardboard. High fuel injection pressure can cause personal injury if contact is made with the skin. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Description > Page 7392 Fuel Supply Line: Description and Operation Operation OPERATION High-Pressure Lines CAUTION: The high-pressure fuel lines must be held securely in the brace. The lines cannot contact each other or other components. Do not attempt to weld high-pressure fuel lines or to repair lines that are damaged. If lines are ever kinked or bent, they must be replaced. Use only the recommended lines when replacement of high-pressure fuel line is necessary. High-pressure fuel lines deliver fuel (under pressure) of up to approximately 180,000 kPa (26,107 PSI) from the injection pump to the fuel injectors. The lines expand and contract from the high-pressure fuel pulses generated during the injection process. All high-pressure fuel lines are of the same length and inside diameter. Correct high-pressure fuel line usage and installation is critical to smooth engine operation. WARNING: Use extreme caution when inspecting for high-pressure fuel leaks. Inspect for high-pressure fuel leaks with a sheet of cardboard. High fuel injection pressure can cause personal injury if contact is made with the skin. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Removal Fuel Supply Line: Service and Repair Removal REMOVAL CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only. If removing fuel line at either No. 1 or No. 2 cylinder, the air inlet housing/EGR valve assembly must first be removed from the top of the intake manifold. 1. Disconnect both negative battery cables from both batteries. Cover and isolate ends of cables. 2. Thoroughly clean fuel lines at both ends. CAUTION: When loosening or tightening high-pressure lines attached to a separate fitting (11), use a back-up wrench on fitting (12). Do not allow fittings (12) to rotate. Damage to both fuel line and fitting will result. 3. If removing fuel line at # 6 cylinder, a bracket (4) is located above fuel line connection at cylinder head. Two bolts (3) secure this bracket to rear of cylinder head. The upper bolt hole is slotted. Loosen (but do not remove) these two bracket bolts. Tilt bracket down to gain access to # 6 fuel line connection. 4. If removing fuel line at either #1 or #2 cylinder, the air inlet housing/EGR assembly must first be removed from top of intake manifold. 5. Place shop towels around fuel lines at fuel rail and injectors. If possible, do not allow fuel to drip down side of engine. 6. Carefully remove each fuel line from engine. Note position of each while removing. Do not bend lines while removing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Removal > Page 7395 Fuel Supply Line: Service and Repair Installation INSTALLATION All high-pressure fuel lines are of the same length and inside diameter. Correct high-pressure fuel line usage and installation is critical to smooth engine operation. CAUTION: Anytime a high-pressure line is removed from the engine, its fuel connector nut (12) at the cylinder head must first be retorqued. 1. Tighten nuts (12) at high pressure injector connector nut at the cylinder head. Torque nut to 50 Nm (37 ft. lbs.). 2. Position proper fuel line to proper injector on engine. Tighten fittings hand tight at both ends of line. 3. Tighten fuel line at cylinder head. Torque nut to 40 Nm (30 ft. lbs.). 4. Tighten fuel line nuts at fuel rail to 40 Nm (30 ft. lbs.). 5. If fuel line at No. 6 cylinder has been replaced, tilt metal bracket (4) upward and tighten two bolts (3) at rear of cylinder head. Tighten to 43 Nm (32 ft. lbs.). 6. If necessary, install EGR valve/air intake manifold assembly. 7. Connect both negative battery cables to both batteries. 8. Prime fuel system. 9. Check lines/fittings for leaks. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7401 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7402 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7403 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7404 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7405 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7406 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7407 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7408 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7409 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7410 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7411 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7412 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7413 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7414 Fuel Gauge Sender: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7415 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7416 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7417 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 7418 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Page 7419 Fuel Gauge Sender: Description and Operation DESCRIPTION The fuel tank module is installed in the top of the fuel tank. The fuel tank module contains the following components: - An electric fuel transfer (lift) pump - Fuel reservoir - A separate in-tank fuel filter - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection - A special lockring to retain module to fuel tank - Fuel return line connection. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Removal Fuel Gauge Sender: Service and Repair Removal REMOVAL 1. Drain and remove fuel tank. 2. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose. 3. Position Special Tool 9340 (3) into notches on outside edge of lockring (5). 4. Install 1/2 inch drive breaker bar (1) to tool 9340 (3). 5. Rotate breaker bar counterclockwise to remove lockring. 6. Remove lockring. The module will spring up slightly when lockring is removed. 7. Remove module from fuel tank. Be careful not to bend float arm while removing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Removal > Page 7422 Fuel Gauge Sender: Service and Repair Installation INSTALLATION CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced. 1. Using a new seal (gasket), position fuel pump module into opening in fuel tank. 2. Position lockring (5) over top of fuel pump module. 3. Rotate module until embossed alignment arrow points to center alignment mark. This step must be performed to prevent float from contacting side of fuel tank. Also be sure fuel fitting on top of pump module is pointed to drivers side of vehicle. 4. Install Special Tool 9340 (3) to lockring. 5. Install 1/2 inch drive breaker (1) into Special Tool 9340 (3). 6. Tighten lockring (clockwise) until all seven notches have engaged. 7. Install fuel tank. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > Recalls for Fuel Tank Mounting Straps: > G34 > Nov > 07 > Recall - Fuel Tank Strap Replacement Technical Service Bulletin # G34 Date: 071101 Recall - Fuel Tank Strap Replacement November 2007 Dealer Service Instructions for: Safety Recall G34 Fuel Tank Straps Models 2007 (DC) Dodge Ram 3500 Series Cab and Chassis NOTE: This recall applies only to the above vehicles equipped with a 23 gallon fuel tank (sales code NFA) built at the Saltillo Assembly Plant ("G" in the 11th VIN Position). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The fuel tank straps on about 550 of the above vehicles may have been improperly manufactured and could separate. This can cause the fuel tank to loosen and leak fuel. Fuel leakage in the presence of an ignition source can result in an underbody fire. Repair Both fuel tank straps must be replaced. Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > Recalls for Fuel Tank Mounting Straps: > G34 > Nov > 07 > Recall - Fuel Tank Strap Replacement > Page 7431 Use the labor operation number and time allowance shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC Service Procedure 1. Raise the vehicle on an appropriate hoist. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > Recalls for Fuel Tank Mounting Straps: > G34 > Nov > 07 > Recall - Fuel Tank Strap Replacement > Page 7432 2. Place a transmission jack under the front of the fuel tank to support the fuel tank (Figure 1). CAUTION: Place a block of wood on the transmission jack to prevent damage to the fuel tank. 3. Remove and discard the front fuel tank strap nut. 4. Using the transmission jack, lower the front of the fuel tank slightly. 5. Remove and discard the original front fuel tank strap. 6. Insert the new front fuel tank strap into the frame side slot and align the strap over the fuel tank stud. 7. Hand-start the new fuel tank strap nut. 8. Carefully raise the fuel tank into position using the transmission jack. 9. Tighten the fuel tank strap nut to 45 ft. lbs. (61 N.m). 10. Lower the transmission jack and move it to the rear of the fuel tank. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > Recalls for Fuel Tank Mounting Straps: > G34 > Nov > 07 > Recall - Fuel Tank Strap Replacement > Page 7433 11. Place a transmission jack under the back of the fuel tank to support the tank (Figure 2). CAUTION: Place a block of wood on the transmission jack to prevent damage to the fuel tank. 12. Remove and discard the rear fuel tank strap nut. 13. Using the transmission jack, lower the back of the fuel tank slightly. 14. Remove and discard the original rear fuel tank strap. 15. Insert the new rear fuel tank strap into the frame side slot and align the strap over the fuel tank stud. 16. Hand-start the new fuel tank strap nut. 17. Carefully raise the fuel tank into position using the transmission jack. 18. Tighten the fuel tank strap nut to 45 ft. lbs. (61 N.m). 19. Lower and remove the transmission jack. 20. Lower the vehicle from the hoist. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > Recalls for Fuel Tank Mounting Straps: > G34 > Nov > 07 > Recall - Fuel Tank Strap Replacement > Page 7434 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > Recalls for Fuel Tank Mounting Straps: > NHTSA07V472000 > Oct > 07 > Recall 07V472000: Fuel Tank Strap Replacement Fuel Tank Mounting Straps: Recalls Recall 07V472000: Fuel Tank Strap Replacement Make/Models: Model/Build Years: DODGE/RAM 3500 2007 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V472000 MFR'S REPORT DATE: October 02, 2007 COMPONENT: Fuel System, Gasoline: Storage: Tank Assembly POTENTIAL NUMBER OF UNITS AFFECTED: 564 SUMMARY: On certain cab/chassis pickup trucks equipped with an optional 23 gallon fuel tank, the fuel tank straps were improperly manufactured and could separate. This can cause the fuel tank to loosen and leak fuel. CONSEQUENCE: Fuel leakage in the presence of an ignition source can result in an underbody fire. REMEDY: Dealers will replace the fuel tank retention straps and fasteners free of charge. The recall is expected to begin during November 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. G34. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Mounting Straps: > G34 > Nov > 07 > Recall - Fuel Tank Strap Replacement Technical Service Bulletin # G34 Date: 071101 Recall - Fuel Tank Strap Replacement November 2007 Dealer Service Instructions for: Safety Recall G34 Fuel Tank Straps Models 2007 (DC) Dodge Ram 3500 Series Cab and Chassis NOTE: This recall applies only to the above vehicles equipped with a 23 gallon fuel tank (sales code NFA) built at the Saltillo Assembly Plant ("G" in the 11th VIN Position). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The fuel tank straps on about 550 of the above vehicles may have been improperly manufactured and could separate. This can cause the fuel tank to loosen and leak fuel. Fuel leakage in the presence of an ignition source can result in an underbody fire. Repair Both fuel tank straps must be replaced. Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Mounting Straps: > G34 > Nov > 07 > Recall - Fuel Tank Strap Replacement > Page 7444 Use the labor operation number and time allowance shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC Service Procedure 1. Raise the vehicle on an appropriate hoist. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Mounting Straps: > G34 > Nov > 07 > Recall - Fuel Tank Strap Replacement > Page 7445 2. Place a transmission jack under the front of the fuel tank to support the fuel tank (Figure 1). CAUTION: Place a block of wood on the transmission jack to prevent damage to the fuel tank. 3. Remove and discard the front fuel tank strap nut. 4. Using the transmission jack, lower the front of the fuel tank slightly. 5. Remove and discard the original front fuel tank strap. 6. Insert the new front fuel tank strap into the frame side slot and align the strap over the fuel tank stud. 7. Hand-start the new fuel tank strap nut. 8. Carefully raise the fuel tank into position using the transmission jack. 9. Tighten the fuel tank strap nut to 45 ft. lbs. (61 N.m). 10. Lower the transmission jack and move it to the rear of the fuel tank. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Mounting Straps: > G34 > Nov > 07 > Recall - Fuel Tank Strap Replacement > Page 7446 11. Place a transmission jack under the back of the fuel tank to support the tank (Figure 2). CAUTION: Place a block of wood on the transmission jack to prevent damage to the fuel tank. 12. Remove and discard the rear fuel tank strap nut. 13. Using the transmission jack, lower the back of the fuel tank slightly. 14. Remove and discard the original rear fuel tank strap. 15. Insert the new rear fuel tank strap into the frame side slot and align the strap over the fuel tank stud. 16. Hand-start the new fuel tank strap nut. 17. Carefully raise the fuel tank into position using the transmission jack. 18. Tighten the fuel tank strap nut to 45 ft. lbs. (61 N.m). 19. Lower and remove the transmission jack. 20. Lower the vehicle from the hoist. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Mounting Straps: > G34 > Nov > 07 > Recall - Fuel Tank Strap Replacement > Page 7447 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Mounting Straps: > NHTSA07V472000 > Oct > 07 > Recall 07V472000: Fuel Tank Strap Replacement Fuel Tank Mounting Straps: All Technical Service Bulletins Recall 07V472000: Fuel Tank Strap Replacement Make/Models: Model/Build Years: DODGE/RAM 3500 2007 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V472000 MFR'S REPORT DATE: October 02, 2007 COMPONENT: Fuel System, Gasoline: Storage: Tank Assembly POTENTIAL NUMBER OF UNITS AFFECTED: 564 SUMMARY: On certain cab/chassis pickup trucks equipped with an optional 23 gallon fuel tank, the fuel tank straps were improperly manufactured and could separate. This can cause the fuel tank to loosen and leak fuel. CONSEQUENCE: Fuel leakage in the presence of an ignition source can result in an underbody fire. REMEDY: Dealers will replace the fuel tank retention straps and fasteners free of charge. The recall is expected to begin during November 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. G34. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit Fuel Tank Vent: Technical Service Bulletins Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit NUMBER: 14-004-11 GROUP: Fuel System DATE: April 01, 2011 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-002-10, DATED FEBRUARY 11, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE NEW PARTS. SUBJECT: Heavy Duty Filtration MOPAR Retrofit or Add On Parts Available MODELS: 2003 - 2009 (D1/DH/DR) Ram Truck (2500/3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH/DR vehicles equipped with a 5.9L Cummins engine built from 2003 model year (sales codes ETH, ETC) and DC/DH/D1/vehicles equipped with a 6.7L Cummins engine built from 2007 model year (sales code ETJ). DISCUSSION: Several fuel system add-on or retrofit parts are available to enhance the filtering capability for customers exposing their vehicles to extremely dirty conditions. Description of parts available for Cummins diesel equipped vehicles are listed below: ^ **Severe duty, frame mounted fuel filter** (application for 2004.5 - 2009 Pickup & 2007 - 2010 Cab Chassis DC). ^ 6.7L up-graded (5 & 10 micron filter-in-filter) fuel filter to retrofit earlier models (shell and element). ^ 6.7L Element only, fuel filter. ^ 5.9L & 6.7L Add-on or up-graded fuel tank vent hose kit with vent cap. ^ Filter for fuel tank vent hose, (replaces vent cap). ^ 5.9L up-graded air filter. This filter is similar in design to the current 6.7L air filter. NOTE: Do not sell p/n 05183410AA fuel filter for (bottom load style) 6.7L engines. Use 68061633AA shell and filter. NOTE: The maintenance intervals for the fuel filter(s) is 15,000 miles, 400 engine hours or 12 Months, (whichever occurs first) or more often as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 7456 PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Description and Operation Fuel Tank Unit: Description and Operation DESCRIPTION The fuel tank module is installed in the top of the fuel tank. The fuel tank module contains the following components: - An electric fuel transfer (lift) pump - Fuel reservoir - A separate in-tank fuel filter - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection - A special lockring to retain module to fuel tank - Fuel return line connection. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Removal Fuel Tank Unit: Service and Repair Removal REMOVAL 1. Drain and remove fuel tank. 2. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose. 3. Position Special Tool 9340 (3) into notches on outside edge of lockring (5). 4. Install 1/2 inch drive breaker bar (1) to tool 9340 (3). 5. Rotate breaker bar counterclockwise to remove lockring. 6. Remove lockring. The module will spring up slightly when lockring is removed. 7. Remove module from fuel tank. Be careful not to bend float arm while removing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Removal > Page 7462 Fuel Tank Unit: Service and Repair Installation INSTALLATION CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced. 1. Using a new seal (gasket), position fuel pump module into opening in fuel tank. 2. Position lockring (5) over top of fuel pump module. 3. Rotate module until embossed alignment arrow points to center alignment mark. This step must be performed to prevent float from contacting side of fuel tank. Also be sure fuel fitting on top of pump module is pointed to drivers side of vehicle. 4. Install Special Tool 9340 (3) to lockring. 5. Install 1/2 inch drive breaker (1) into Special Tool 9340 (3). 6. Tighten lockring (clockwise) until all seven notches have engaged. 7. Install fuel tank. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Locations Fuel/Water Separator: Locations The fuel filter/water separator assembly is located on left side of engine above the starter motor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Description and Operation > Description Fuel/Water Separator: Description and Operation Description DESCRIPTION The fuel filter/water separator assembly is located on left side of engine above the starter motor. The assembly also includes the fuel heater, water drain valve, Water-In-Fuel (WIF) sensor and a quick-connect fittings attached at the side of the fuel filter canister. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Description and Operation > Description > Page 7468 Fuel/Water Separator: Description and Operation Operation OPERATION The fuel filter/water separator protects the fuel injection pump by removing water and contaminants from the fuel. The construction of the filter/separator allows fuel to pass through it, but helps prevent moisture (water) from doing so. Moisture collects at the bottom of the filter. Refer to the maintenance schedules for the recommended fuel filter replacement intervals. For draining of water from canister, refer to Fuel/Water Separator Removal. There is a screened quick-connect fitting that is attached at the side of the fuel filter canister. It provides additional filtering for the high pressure fuel system components. A Water-In-Fuel (WIF) sensor is attached to the bottom of fuel filter element. The fuel heater is installed into the side of the filter/separator housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service and Repair > Removal Fuel/Water Separator: Service and Repair Removal REMOVAL Refer to maintenance schedules for recommended fuel filter replacement intervals. Draining water from fuel filter canister: The housing drain valve (3) serves two purposes. One is to partially drain the filter housing of excess water. The other is to partially drain the housing for fuel filter or heater element replacement. The filter housing (1) should be partially drained whenever the water-in-fuel warning lamp remains illuminated. (Note that lamp will be illuminated for approximately two seconds when ignition key is initially placed in ON position for a bulb check). 1. A drain hose (4) is located at the bottom of drain valve. Place drain pan under drain hose. 2. With engine not running, rotate drain valve (3) approximately two revolutions to open it. Leave open until all water and contaminants have been removed and clean fuel exits. Hand tighten drain valve after tightening. 3. If fuel heater element is being replaced, drain housing completely. Dispose of mixture in drain pan according to applicable regulations. 4. After draining operation, close and tighten drain valve (3). 5. Fuel Filter Replacement: a. Remove left front tire/wheel. b. Remove left front wheel splash shield. c. Clean all debris from around filter canister (1) and canister head. d. Disconnect WIF sensor electrical connector (5). e. Open drain valve (3) two complete revolutions. Drain approximately 1 cup of fuel into a waste canister. Dispose of fuel according to environmental regulations. f. Remove drain hose (4) from drain valve (3). g. Use an oil filter type wrench to loosen filter (1). Continue removing filter by hand. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service and Repair > Removal > Page 7471 6. After fuel filter removal, also check and clean secondary filter screen. Press button (2) on quick-connect fitting. Disconnect fitting (1) from fitting (3). Unscrew fitting (3) from canister head to expose screen. 7. Clean screen (5) and check condition of O-ring (6). 8. Water-In-Fuel (WIF) Sensor Replacement: The WIF sensor (2) is located on the bottom of the fuel filter housing. The WIF sensor is not a separately serviceable item. If diagnostics have led you to replace this sensor, then the whole fuel filter assembly (1) needs to be changed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service and Repair > Removal > Page 7472 9. Fuel Heater Element Replacement: The heater element (2) is located in the fuel filter housing (4). a. Drain fuel filter. See previous steps. b. Disconnect electrical connector (1). c. Remove two mounting screws (3). d. Remove fuel heater (2). 10. Check condition of fuel heater O-ring (2). 11. Drain Valve Replacement: The Drain Valve is located on the bottom of the fuel filter. This is not a separately serviceable item. If replacement is necessary, replace the entire filter/filter canister assembly. 12. Fuel Filter Head (Housing) Replacement: a. If equipped, remove transmission dipstick tube from filter housing. b. Remove all low-pressure fuel lines at filter housing c. Remove housing from cylinder head. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service and Repair > Removal > Page 7473 Fuel/Water Separator: Service and Repair Installation INSTALLATION Refer to maintenance schedules for recommended fuel filter replacement intervals. 1. Fuel Filter: CAUTION: Do not pre-fill the fuel filter with fuel. Severe damage to fuel system and injection system components may result. a. The engine has a self-priming low-pressure fuel system. b. Lubricate new fuel filter O-ring with clean engine oil. c. Position new fuel filter/canister assembly (1) to housing. d. Rotate fuel filter/canister assembly (1) until it comes to a hard stop. e. Tighten the filter element an additional half-inch of rotation. f. Connect WIF sensor electrical connector (5). g. Attach drain hose (4) to drain valve (3). h. Install left front tire/wheel. i. Install left front wheel splash shield. 2. Clean screen (5). 3. Check condition of new O-ring (6) and lubricate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service and Repair > Removal > Page 7474 4. Install screen assembly into housing and tighten fitting (3) to 20 ft. lbs. (27 Nm). 5. Connect quick connect fuel supply line (1) to fitting (3). 6. Fuel Heater Element: a. Check condition of O-ring (2). b. Lubricate new element O-ring before installation. 7. Install fuel heater element (3) into fuel filter housing (4). 8. Install two fuel heater mounting screws (3) and tighten to 60 in lbs. (6.8 Nm). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service and Repair > Removal > Page 7475 9. Connect electrical connector (1). 10. Fuel Filter Head (Housing): a. Install fuel filter head to cylinder head. Tighten bolts to 32 Nm (24 ft. lbs.) torque. b. Replace sealing washers on banjo bolts and install all low-pressure fuel lines to filter housing. Tighten banjo bolts to 24 Nm (18 ft. lbs.) torque. Tighten quick-connect fitting to 27 Nm (20 ft. lbs.) torque. c. If equipped, install transmission dipstick tube to filter housing. Tighten bolt to 10 Nm (8 ft. lbs.) torque. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations High Idle Switch: Locations Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 7479 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 7480 High Idle Switch: Diagrams Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 7481 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Intake Air Heater Relay > Component Information > Locations Intake Air Heater Relay: Locations Component ID: 240 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 FUSED B(+) A19 10DG 30 FUSED B(+) A19 10RD/YL 85 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 86 GROUND Z174 18BK 86 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 87 INTAKE AIR HEATER RELAY OUTPUT A58 4BK Component Location - 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Intake Air Heater Relay > Component Information > Locations > Page 7486 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Intake Air Heater Relay > Component Information > Locations > Page 7487 Intake Air Heater Relay: Diagrams Component ID: 240 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 FUSED B(+) A19 10DG 30 FUSED B(+) A19 10RD/YL 85 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 86 GROUND Z174 18BK 86 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 87 INTAKE AIR HEATER RELAY OUTPUT A58 4BK Component Location - 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Intake Air Heater Relay > Component Information > Locations > Page 7488 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Intake Air Heater Relay > Component Information > Locations > Page 7489 Intake Air Heater Relay: Description and Operation OPERATION The Engine Control Module (ECM) operates the heating element through the intake manifold air heater relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Intake Air Heater Relay > Component Information > Service and Repair > Removal Intake Air Heater Relay: Service and Repair Removal REMOVAL The intake manifold air heater relay (5) is located in the engine compartment. It attached to a bracket. This bracket is attached to the right battery tray (3). The mounting bracket and relay is replaced as an assembly. 1. Disconnect both negative battery cables at both batteries. 2. Disconnect relay trigger wires (4) at relays. Note position of wiring before removing. 3. Remove nuts (2) at cable connectors and disconnect cables (1) from mounting studs. Note position of cables before removing. 4. Remove two relay mounting bracket screws (6) and remove relay assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Intake Air Heater Relay > Component Information > Service and Repair > Removal > Page 7492 Intake Air Heater Relay: Service and Repair Installation INSTALLATION The intake manifold air heater relay (5) is located in the engine compartment. It attached to a bracket. This bracket is attached to the right battery tray (3). The mounting bracket and relay is replaced as an assembly. 1. Position relay and install two relay mounting bracket screws (6). 2. Position cables (1) to mounting studs and install nuts (2). 3. Connect relay trigger wires (4) at relays. 4. Connect both negative battery cables to both batteries. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 7496 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 7497 Main Relay (Computer/Fuel System): Diagrams Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 7498 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 7499 Main Relay (Computer/Fuel System): Testing and Inspection Fig.1 ASD And Fuel Pump Relay Terminals-Type 1 Fig.2 ASD And Fuel Pump Relay Terminals-Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 7500 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 7505 8w-30-17 Connector C1 pin 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7508 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7509 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7510 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7511 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7512 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7513 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7514 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7515 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7516 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7517 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7518 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7519 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7520 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7521 Fuel Pump Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7522 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7523 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7524 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7525 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7526 Fuel Pump Relay: Connector Views Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 7527 Fuel Pump Relay: Description and Operation The fuel transfer pump (fuel lift pump) is part of the fuel pump module. The fuel pump module is located in the fuel tank. The 12-volt electric pump is operated and controlled by the Engine Control Module (ECM). The ECM controls a relay in the intelligent Power Module (IPM) for transfer pump operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations Intake Air Heater Relay: Locations Component ID: 240 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 FUSED B(+) A19 10DG 30 FUSED B(+) A19 10RD/YL 85 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 86 GROUND Z174 18BK 86 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 87 INTAKE AIR HEATER RELAY OUTPUT A58 4BK Component Location - 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Page 7531 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Page 7532 Intake Air Heater Relay: Diagrams Component ID: 240 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 FUSED B(+) A19 10DG 30 FUSED B(+) A19 10RD/YL 85 INTAKE AIR HEATER RELAY CONTROL K174 18BR/YL 86 GROUND Z174 18BK 86 INTAKE AIR HEATER RELAY CONTROL RETURN K974 18BR/BK 87 INTAKE AIR HEATER RELAY OUTPUT A58 4BK Component Location - 4 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Page 7533 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Page 7534 Intake Air Heater Relay: Description and Operation OPERATION The Engine Control Module (ECM) operates the heating element through the intake manifold air heater relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Service and Repair > Removal Intake Air Heater Relay: Service and Repair Removal REMOVAL The intake manifold air heater relay (5) is located in the engine compartment. It attached to a bracket. This bracket is attached to the right battery tray (3). The mounting bracket and relay is replaced as an assembly. 1. Disconnect both negative battery cables at both batteries. 2. Disconnect relay trigger wires (4) at relays. Note position of wiring before removing. 3. Remove nuts (2) at cable connectors and disconnect cables (1) from mounting studs. Note position of cables before removing. 4. Remove two relay mounting bracket screws (6) and remove relay assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Service and Repair > Removal > Page 7537 Intake Air Heater Relay: Service and Repair Installation INSTALLATION The intake manifold air heater relay (5) is located in the engine compartment. It attached to a bracket. This bracket is attached to the right battery tray (3). The mounting bracket and relay is replaced as an assembly. 1. Position relay and install two relay mounting bracket screws (6). 2. Position cables (1) to mounting studs and install nuts (2). 3. Connect relay trigger wires (4) at relays. 4. Connect both negative battery cables to both batteries. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 7541 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 7542 Main Relay (Computer/Fuel System): Diagrams Component ID: 241 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Description Circuit 1 FUSED B(+) A118 18RD/OR 2 FUSED B(+) A118 18RD/OR 3-4 SMART POWER RELAY FEED F348 16PK/OR 5 SMART POWER RELAY RETURN K348 18BR Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 7543 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 7544 Main Relay (Computer/Fuel System): Testing and Inspection Fig.1 ASD And Fuel Pump Relay Terminals-Type 1 Fig.2 ASD And Fuel Pump Relay Terminals-Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 7545 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 7550 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 7551 Accelerator Pedal Position Sensor: Diagrams Component ID: 386 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL Pin Description Circuit 1 5 VOLT SUPPLY K852 20BR/VT 2 APPS NO. 1 SIGNAL K23 20BR/WT 3 APPS NO. 1 RETURN K167 20BR/YL 4 APPS NO. 2 RETURN K400 20BR/VT 5 APPS NO. 2 SIGNAL K29 20WT/BR 6 5 VOLT SUPPLY F856 20YL/PK 6 5 VOLT SUPPLY K854 20VT/BR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 7552 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 7555 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) provides the Engine Control Module (ECM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 7558 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 7562 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 7563 Air Flow Meter/Sensor: Diagrams Component ID: 412 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 MASS AIR FLOW SENSOR SIGNAL K157 18BR/OR 2 SMART POWER RELAY FEED F348 16PK/OR 3 SENSOR GROUND K916 18BR/OR 4-Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 7564 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 7565 Air Flow Meter/Sensor: Description and Operation OPERATION The Mass Airflow (MAF) sensor is a frequency based device. A constant voltage is applied to a heated wire on the sensor. This wire is positioned in the air cleaner air stream and is heated by the electrical current that the voltage produces. As air flows across it, it cools down. The heated wire or film is a positive temperature coefficient resistor. This means that its resistance drops when its temperature drops. The drop in resistance allows more current to flow through it in order to maintain the programmed temperature. This current is changed to a frequency which is sent to the Engine Control Module (ECM) and interpreted as air flow. Adjustments for air temperature and humidity are taken into consideration because they also affect the temperature of the heated wire or film. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL The Mass Airflow Sensor (5) is located on the air cleaner cover (8). 1. Disconnect electrical connector (6) at sensor. 2. Remove two mounting screws (4). 3. Remove sensor from air cleaner cover. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 7568 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (4). 4. Install electrical connector (6). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure Fuel Pressure Sensor/Switch: Locations Sensor-Fuel Rail Pressure Component ID: 404 Component : SENSOR-FUEL RAIL PRESSURE Connector: Name : SENSOR-FUEL RAIL PRESSURE Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL RAIL SENSOR RETURN K915 18BR/WT Pin Description Circuit 1 SENSOR GROUND K916 18BR/OR 2 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 3 5 VOLT SUPPLY F855 18PK/YL Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure > Page 7573 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure > Page 7574 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Sensor-Fuel Rail Pressure > Page 7575 Fuel Pressure Sensor/Switch: Locations Sensor-Fuel Pressure The fuel pressure sensor (1) is mounted to the rear of the fuel rail (6). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 7576 Fuel Pressure Sensor/Switch: Diagrams Component ID: 404 Component : SENSOR-FUEL RAIL PRESSURE Connector: Name : SENSOR-FUEL RAIL PRESSURE Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 FUEL RAIL SENSOR RETURN K915 18BR/WT Pin Description Circuit 1 SENSOR GROUND K916 18BR/OR 2 FUEL RAIL SENSOR SIGNAL K181 18BR/YL 3 5 VOLT SUPPLY F855 18PK/YL Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 7577 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 7578 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 7579 Fuel Pressure Sensor/Switch: Description and Operation OPERATION The fuel pressure sensor monitors actual high-pressure within the fuel rail. An output signal from this sensor (relating to fuel pressure) is sent to the Engine Control Module (ECM). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal Fuel Pressure Sensor/Switch: Service and Repair Removal REMOVAL The fuel pressure sensor (1) is mounted to the rear of the fuel rail (6). 1. Remove two bolts (3) and bracket (4) at rear of cylinder head. 2. Remove engine oil dipstick tube mounting bolts. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal > Page 7582 3. Disconnect electrical connector (2) at sensor. 4. Remove sensor (1) from fuel rail. 5. Inspect sensor sealing surface. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal > Page 7583 Fuel Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Inspect fuel pressure sensor sealing surface. 2. Lubricate sensor threads with clean diesel fuel. 3. Install sensor (1) into fuel rail. 4. To prevent leaks, sensor must be tightened to 70 Nm (52 ft. lbs.). 5. Connect electrical connector (2) to sensor. 6. Install rear engine lift bracket (4) and bolts (3). Tighten to 77 Nm (57 ft. lbs.). 7. Install engine oil dipstick tube mounting bolts. 8. Start engine and check for fuel leaks. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations High Idle Switch: Locations Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 7587 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 7588 High Idle Switch: Diagrams Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 7589 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Pick Up Models Turbo Boost Sensor: Locations Pick Up Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Pick Up Models > Page 7594 Turbo Boost Sensor: Locations Cab/Chassis Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Page 7595 Turbo Boost Sensor: Description and Operation OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP Turbo Boost Sensor: Service and Repair Sensor-Temperature/Pressure-MAP Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Removal-Pick Up Models REMOVAL-PICK UP MODELS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP > Page 7598 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP > Page 7599 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP > Page 7600 Turbo Boost Sensor: Service and Repair Sensor-Turbocharger Speed Removal REMOVAL 1. Disconnect negative battery cable. 2. Disconnect speed sensor electrical connector. 3. Remove turbocharger speed sensor mounting bolt (1). 4. Remove turbocharger speed sensor (2). Installation INSTALLATION 1. Install turbocharger speed sensor. 2. Install turbocharger speed sensor mounting bolt. 3. Tighten bolt to 10 Nm (89 in. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Speed Sensor > Component Information > Locations Turbocharger Speed Sensor: Locations Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Speed Sensor > Component Information > Locations > Page 7604 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Speed Sensor > Component Information > Locations > Page 7605 Turbocharger Speed Sensor: Diagrams Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Speed Sensor > Component Information > Locations > Page 7606 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations Throttle Body: Locations Component ID: 495 Component : THROTTLE BODY Connector: Name : THROTTLE BODY Color : BLACK # of pins : 6 Qualifier : (3.7L) Pin Description Circuit 1 ETC MOTOR (+) K447 20TN/YL 2 5 VOLT SUPPLY F855 20PK/YL 3 TP SENSOR RETURN K922 20BR/DB 4 ETC MOTOR (-) K448 20TN/OR 5 TP NO. 2 SIGNAL K122 20BR/DG 6 TP NO. 1 SIGNAL K22 20BR/OR Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 7610 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 7611 Component Location - 10 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 7612 Connector: Name : THROTTLE BODY Color : BLACK # of pins : 6 Qualifier : (5.7L) Pin Description Circuit 1 TP NO. 1 SIGNAL K22 20BR/OR 2 5 VOLT SUPPLY F855 20PK/YL 3 ETC MOTOR (+) K447 20TN/YL 4 TP NO. 2 SIGNAL K122 20BR/DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 7613 5 ETC MOTOR (-) K448 20TN/OR 6 TP SENSOR RETURN K922 20BR/DB Component Location - 8 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 7614 Component Location - 10 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 7615 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 7616 Throttle Body: Diagrams Component ID: 495 Component : THROTTLE BODY Connector: Name : THROTTLE BODY Color : BLACK # of pins : 6 Qualifier : (3.7L) Pin Description Circuit 1 ETC MOTOR (+) K447 20TN/YL 2 5 VOLT SUPPLY F855 20PK/YL 3 TP SENSOR RETURN K922 20BR/DB 4 ETC MOTOR (-) K448 20TN/OR 5 TP NO. 2 SIGNAL K122 20BR/DG 6 TP NO. 1 SIGNAL K22 20BR/OR Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 7617 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 7618 Component Location - 10 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 7619 Connector: Name : THROTTLE BODY Color : BLACK # of pins : 6 Qualifier : (5.7L) Pin Description Circuit 1 TP NO. 1 SIGNAL K22 20BR/OR 2 5 VOLT SUPPLY F855 20PK/YL 3 ETC MOTOR (+) K447 20TN/YL 4 TP NO. 2 SIGNAL K122 20BR/DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 7620 5 ETC MOTOR (-) K448 20TN/OR 6 TP SENSOR RETURN K922 20BR/DB Component Location - 8 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 7621 Component Location - 10 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 7622 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Description and Operation > Description Intercooler: Description and Operation Description DESCRIPTION The charge air system consists of the charge air cooler piping, charge air cooler and intake air grid heater. The Charge Air Cooler is a heat exchanger that uses air flow from vehicle motion to dissipate heat from the intake air. As the turbocharger increases air pressure, the air temperature increases. Lowering the intake air temperature increases engine efficiency and power. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Description and Operation > Description > Page 7628 Intercooler: Description and Operation Operation OPERATION Intake air is drawn through the air cleaner and into the turbocharger compressor housing. Pressurized air from the turbocharger then flows forward through the charge air cooler located in front of the radiator. From the charge air cooler the air flows back into the intake manifold. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Description and Operation > Page 7629 Intercooler: Testing and Inspection CHARGE AIR COOLER SYSTEM - LEAKS Low turbocharger boost pressure and low engine performance can be caused by leaks in the charge air cooler or plumbing. Fuel staining on the exhaust manifold can also be an indication that there are leaks in the air system. The following procedure outlines how to check for leaks in the charge air cooler system. This procedure can also be used to check for leaks in the wastegate signal line or the wastegate canister. 1. Loosen clamp and remove air inlet hose from turbocharger. 2. Insert Special Tool 9022 Adapter and tool 9860 into the turbocharger inlet. Tighten tool clamp to 8 Nm (72 in. lbs.). CAUTION: Do not apply more than 138 kPa (20 psi) air pressure to the charge air cooler system, severe damage to the charge air cooler system may occur. 3. Connect a regulated air supply to air fitting on Tool 9022 Adapter. Set air pressure to a Maximum of 138 kPa (20 psi). 4. Using soapy water check the rubber sleeves, charge air cooler and intake manifold for leaks. 5. Using soapy water check for leaks at the wastegate signal line, wastegate canister and wastegate command valve. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Service and Repair > Removal Intercooler: Service and Repair Removal REMOVAL WARNING: IF THE ENGINE WAS JUST TURNED OFF, THE AIR INTAKE SYSTEM TUBES MAY BE HOT. 1. Disconnect the battery negative cables. 2. Discharge the A/C system. 3. Remove the transmission auxiliary cooler. 4. Remove intake air tubing from the charge air cooler. 5. Remove the charge air cooler bolts. Pivot the charge air cooler forward and up to remove. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Service and Repair > Removal > Page 7632 Intercooler: Service and Repair Cleaning CLEANING CAUTION: Do not use caustic or acid based cleaners to clean the charge air cooler. Damage to the charge air cooler will result. NOTE: If internal debris cannot be removed from the cooler, the charge air cooler MUST be replaced. NOTE: Charge air cooler must be a room temperature for this procedure. 1. If the engine experiences a turbocharger failure or any other situation where oil or debris get into the charge air cooler, the charge air cooler must be cleaned internally. 2. Remove charge air cooler. 3. Position the charge air cooler so the inlet and outlet tubes are vertical. 4. Flush the cooler internally with solvent such as mineral spirits in the direction opposite of normal air flow. 5. Shake the cooler and lightly tap on the end tanks with a rubber mallet to dislodge trapped debris. 6. Continue flushing until all debris or oil are removed. 7. Rinse the cooler with hot soapy water to remove any remaining solvent. 8. Rinse thoroughly with clean water and blow dry with compressed air. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Service and Repair > Removal > Page 7633 Intercooler: Service and Repair Inspection INSPECTION Visually inspect the charge air cooler for cracks, holes, or damage. Inspect the tubes, fins, and welds for tears, breaks, or other damage. Replace the charge air cooler if damage is found. Pressure test the charge air cooler, using Charge Air Cooler Tester Kit No. 3824556. This kit is available through Cummins(R) Service Products. Instructions are provided with the kit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Service and Repair > Removal > Page 7634 Intercooler: Service and Repair Installation INSTALLATION 1. Position the charge air cooler. Install the bolts and tighten to 2 Nm (17 in. lbs.) torque. 2. Install the air intake system tubes to the charge air cooler. With the clamps in position, tighten the clamps to 11 Nm (95 in. lbs.) torque. 3. Install the transmission auxiliary cooler (if equipped). 4. Install the A/C condenser (if A/C equipped). 5. Connect the battery negative cables. 6. Start engine and check for boost system leaks. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Locations > Pick Up Models Turbo Boost Sensor: Locations Pick Up Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Locations > Pick Up Models > Page 7639 Turbo Boost Sensor: Locations Cab/Chassis Models The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Locations > Page 7640 Turbo Boost Sensor: Description and Operation OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP Turbo Boost Sensor: Service and Repair Sensor-Temperature/Pressure-MAP Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Removal-Pick Up Models REMOVAL-PICK UP MODELS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP > Page 7643 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP > Page 7644 The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Service and Repair > Sensor-Temperature/Pressure-MAP > Page 7645 Turbo Boost Sensor: Service and Repair Sensor-Turbocharger Speed Removal REMOVAL 1. Disconnect negative battery cable. 2. Disconnect speed sensor electrical connector. 3. Remove turbocharger speed sensor mounting bolt (1). 4. Remove turbocharger speed sensor (2). Installation INSTALLATION 1. Install turbocharger speed sensor. 2. Install turbocharger speed sensor mounting bolt. 3. Tighten bolt to 10 Nm (89 in. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Speed Sensor > Component Information > Locations Turbocharger Speed Sensor: Locations Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Speed Sensor > Component Information > Locations > Page 7649 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Speed Sensor > Component Information > Locations > Page 7650 Turbocharger Speed Sensor: Diagrams Component ID: 432 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 TURBO SPEED SENSOR SIGNAL K540 18BR/GY 2 TURBO SPEED SENSOR GROUND K541 18BR/VT Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Speed Sensor > Component Information > Locations > Page 7651 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Vane Actuator > Component Information > Locations Turbocharger Vane Actuator: Locations Component ID: 3 Component : ACTUATOR-ELECTRONIC TURBO Connector: Name : ACTUATOR-ELECTRONIC TURBO Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 SMART POWER RELAY FEED F348 16PK/OR 2 ACTUATOR GROUND K972 18DB/TN 3 ACTUATOR HIGH DATA LINK D130 18BR/VT 4 ACTUATOR LOW DATA LINK D131 18WT/LG Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Vane Actuator > Component Information > Locations > Page 7655 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Vane Actuator > Component Information > Locations > Page 7656 Turbocharger Vane Actuator: Diagrams Component ID: 3 Component : ACTUATOR-ELECTRONIC TURBO Connector: Name : ACTUATOR-ELECTRONIC TURBO Color : # of pins : 4 Qualifier : (6.7L) Pin Description Circuit 1 SMART POWER RELAY FEED F348 16PK/OR 2 ACTUATOR GROUND K972 18DB/TN 3 ACTUATOR HIGH DATA LINK D130 18BR/VT 4 ACTUATOR LOW DATA LINK D131 18WT/LG Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Vane Actuator > Component Information > Locations > Page 7657 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Actuator > Component Information > Description and Operation Wastegate Actuator: Description and Operation DESCRIPTION - 6.7L ELECTRONICALLY CONTROLLED ACTUATOR The Electronically Controlled Actuator is mounted to the turbocharger bearing housing. The actuator consists of an integrated controller and a gear train that controls the position of the sliding nozzle ring. The actuator uses a signal from the Engine Control Module (ECM) to control the relationship between the sliding nozzle ring and turbine blades. Moving the nozzle ring rearward or forward redirects the exhaust flow so that the turbine wheel spins faster or slower as needed - If the sliding nozzle is moved rearward, the turbocharger builds more pressure (turbine wheel moves faster) - If the sliding nozzle is moved forward, the turbocharger builds less pressure (turbine wheel moves slower) VGT EXHAUST BRAKE The VGT Exhaust Brake works in conjunction with the engine and transmission to provide an integrated braking system to help slow the vehicle. This is commonly referred to as exhaust braking. Braking power is achieved by modulating the sliding nozzle ring to restrict the flow of exhaust gasses from the engine, this will create high back pressure on the engine. The high back pressure creates a high level of resistance to the motion of the pistons within the engine and this resistance is used to reduce engine speed and thus vehicle. The exhaust brake feature will only function when the Exhaust Brake Switch to the ON position. With the switch in the ON Position and the vehicle moving faster then 5 MPH; the exhaust brake will automatically operate when pressure is removed from the accelerator pedal allowing the ECM to see 0% throttle and 0% fuel delivery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Actuator > Component Information > Service and Repair > Removal Wastegate Actuator: Service and Repair Removal 6.7L DIESEL 1. Disconnect the battery negative cables. 2. Raise vehicle on hoist. 3. Drain cooling system. 4. Remove air filter housing. 5. Disconnect turbocharger actuator electrical connector (1). 6. Remove turbocharger actuator mounting bolts (3). 7. Remove turbocharger actuator (2). 8. Clean mounting surface. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Actuator > Component Information > Service and Repair > Removal > Page 7663 Wastegate Actuator: Service and Repair Installation INSTALLATION 1. Clean turbocharger actuator housing and turbocharger mounting surfaces. 2. Position turbocharger actuator in engine compartment so gear will be free to rotate. 3. Connect turbocharger actuator electrical connector. 4. Connect negative battery cable. 5. Using a scan tool, perform TURBO ACTUATOR PRE-ALIGN. NOTE: Do not turn key OFF after performing TURBO ACTUATOR PRE-ALIGN procedure. This holds the actuator gear in position for installation. CAUTION: Use only turbocharger actuator grease. Use of any other type of grease or too much grease may result in damage to turbocharger. 6. Apply grease to turbocharger actuator sector gear in a line across center of all teeth. 7. Install O-ring on turbocharger actuator. 8. Install guide pins on turbocharger. 9. Rotate turbocharger sector gear clockwise and insert small end of turbocharger actuator alignment tool (supplied with new actuator) or 3.175 mm (1/8 in.) drill, through sector gear until it engages the alignment hole in turbocharger bearing housing and sector gear will not rotate. If alignment pin does not engage hole in turbocharger bearing housing, variable geometry mechanism is not opening completely. 10. Remove pin from turbocharger actuator sector gear. Turbocharger actuator sector gear must stay in this position, rotated fully clockwise while installing actuator. 11. Position turbocharger actuator on guide pins and install. 12. Install two mounting screws. Hand tighten only. 13. Remove guide pins. Install remaining two mounting screws. Tighten mounting screws in a cross pattern to 11 Nm (96 in. lbs.). 14. Using scan tool, perform TURBO ACTUATOR SELF CALIBRATE procedure. NOTE: If the TURBO ACTUATOR SELF CALIBRATE procedure fails, remove actuator and repeat installation one additional time. If this fails to clear error, replace turbocharger. 15. Place ignition in the OFF position. 16. Install air filter housing. 17. Fill cooling system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Solenoid > Component Information > Locations Wastegate Solenoid: Locations Component ID: 448 Component : SOLENOID-WASTEGATE Connector: Name : SOLENOID-WASTEGATE Color : # of pins : 2 Qualifier : (DIESEL) A WASTEGATE SOLENOID CONTROL K139 18DB B FUSED B(+) A212 18PK/YL Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Solenoid > Component Information > Locations > Page 7667 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Solenoid > Component Information > Locations > Page 7668 Wastegate Solenoid: Diagrams Component ID: 448 Component : SOLENOID-WASTEGATE Connector: Name : SOLENOID-WASTEGATE Color : # of pins : 2 Qualifier : (DIESEL) A WASTEGATE SOLENOID CONTROL K139 18DB B FUSED B(+) A212 18PK/YL Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Solenoid > Component Information > Locations > Page 7669 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications DESCRIPTION The cylinder block is constructed of cast iron. The casting is a skirted design which incorporates longitudal ribs for superior strength and noise reduction. The block incorporates metric straight thread o-ring fittings at lubrication oil access points. The engine is manufactured with the cylinders being a non-sleeved type cylinder. The cylinders are numbered front to rear ; 1 to 6. The firing order is 1-5-3-6-2-4. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > System Information > Specifications Ignition Timing: Specifications IGNITION TIMING Ignition timing is not adjustable on any engine. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7680 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7681 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7682 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7683 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7684 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7685 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7686 Camshaft Position Sensor: Diagrams Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7687 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7688 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7689 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7690 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7691 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7692 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) is located below the fuel injection pump. It is bolted to the back of the timing gear cover. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 7695 Camshaft Position Sensor: Description and Operation Operation 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) contains a hall effect device. A rotating target wheel (tonewheel) for the CMP is located on the front timing gear. This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CMP. When the leading edge of the tonewheel notch passes the tip of the CMP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CMP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The CMP provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses the CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal Camshaft Position Sensor: Service and Repair Removal 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) on the diesel engine is located below the fuel injection pump (1). It is bolted to the back of the timing gear cover. 1. Disconnect electrical connector (5) at CMP sensor. 2. Remove sensor mounting bolt (6). 3. Carefully twist sensor from timing gear cover. 4. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 7698 Camshaft Position Sensor: Service and Repair Installation 5.9L/6.7L DIESEL The CMP (1) is located on the back of the timing gear cover. 1. Clean out machined hole in back of timing gear cover. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into timing gear cover with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to back of timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in.lbs.). 5. Connect electrical connector to sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information > Description and Operation > Description Condenser: Description and Operation Description DESCRIPTION One coil capacitor (1) is used. It is located in the right-rear section of the engine compartment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information > Description and Operation > Description > Page 7703 Condenser: Description and Operation Operation OPERATION The coil capacitor(s) help dampen the amount of conducted electrical noise to the camshaft position sensor, crankshaft position sensor, and throttle position sensor. This noise is generated on the 12V supply wire to the ignition coils and fuel injectors. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information > Service and Repair > Removal Condenser: Service and Repair Removal REMOVAL The coil capacitor is located in the right-rear section of the engine compartment. It is attached with a mounting stud and nut. 1. Disconnect electrical connector (5) at capacitor. 2. Remove mounting nut and remove ground strap. 3. Remove capacitor (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information > Service and Repair > Removal > Page 7706 Condenser: Service and Repair Installation INSTALLATION 1. Position capacitor (1) to mounting stud (2). 2. Position ground strap (3) to mounting stud (2). 3. Tighten nut (4) to 7 Nm (60 in. lbs.) torque. 4. Connect electrical connector (5) to coil capacitor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7710 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7711 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7712 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7713 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7714 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7715 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7716 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7717 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7718 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7719 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7720 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7721 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7722 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7723 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7724 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7725 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7726 Crankshaft Position Sensor: Diagrams Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7727 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7728 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7729 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7730 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7731 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7732 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7733 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7734 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7735 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7736 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7737 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7738 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7739 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7740 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7741 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7742 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The Crankshaft Position Sensor (CKP) on the diesel engine is attached at the front / left side of the engine next to the engine harmonic balancer (crankshaft damper). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 7745 Crankshaft Position Sensor: Description and Operation Operation OPERATION The Crankshaft Position Sensor (CKP) (5) is the primary engine speed indicator for the engine after the engine is running. The CKP contains a hall effect device. A rotating, notched target wheel (tonewheel) (3) for the CKP is attached to the engine harmonic balancer (2). This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CKP. When the leading edge of the tonewheel notch passes the tip of the CKP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CKP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The Camshaft Position Sensor (CMP) also provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses this CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal Crankshaft Position Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle 2. Disconnect electrical connector (4) at CKP sensor. 3. Remove 1 sensor mounting bolt (3). 4. Remove CKP sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 7748 Crankshaft Position Sensor: Service and Repair Installation INSTALLATION 1. Position and install CKP sensor (5) to engine. 2. Install 1 sensor mounting bolt and tighten to 9 Nm (80 in. lbs.) torque. 3. Install electrical connector (4) to CKP sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation > Description Knock Sensor: Description and Operation Description DESCRIPTION Two knock sensors are bolted into the cylinder block under the intake manifold 3.7L, 4.7L & 8.3L. Two knock sensors are also used with the 5.7L. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation > Description > Page 7753 Knock Sensor: Description and Operation Operation OPERATION Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7758 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7759 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7760 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7761 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7762 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7763 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7764 Camshaft Position Sensor: Diagrams Component ID: 390 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY F855 18PK/YL 2 CMP SENSOR GROUND K944 18BK/GY 2 SENSOR GROUND K916 18BR/OR 3 CMP SIGNAL K44 18DB/GY Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7765 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7766 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7767 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Description Circuit 1 CMP SIGNAL K44 20DB/GY 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F856 20YL/PK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7768 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7769 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 7770 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) is located below the fuel injection pump. It is bolted to the back of the timing gear cover. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 7773 Camshaft Position Sensor: Description and Operation Operation 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) contains a hall effect device. A rotating target wheel (tonewheel) for the CMP is located on the front timing gear. This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CMP. When the leading edge of the tonewheel notch passes the tip of the CMP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CMP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The CMP provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses the CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal Camshaft Position Sensor: Service and Repair Removal 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) on the diesel engine is located below the fuel injection pump (1). It is bolted to the back of the timing gear cover. 1. Disconnect electrical connector (5) at CMP sensor. 2. Remove sensor mounting bolt (6). 3. Carefully twist sensor from timing gear cover. 4. Check condition of sensor O-ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 7776 Camshaft Position Sensor: Service and Repair Installation 5.9L/6.7L DIESEL The CMP (1) is located on the back of the timing gear cover. 1. Clean out machined hole in back of timing gear cover. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into timing gear cover with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to back of timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in.lbs.). 5. Connect electrical connector to sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7780 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7781 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7782 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7783 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7784 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7785 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7786 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7787 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7788 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7789 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7790 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7791 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7792 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7793 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7794 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7795 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7796 Crankshaft Position Sensor: Diagrams Component ID: 392 Component : SENSOR-CRANKSHAFT POSITION Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (3.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7797 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7798 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7799 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7800 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (4.7L) Pin Description Circuit 1 CKP SIGNAL K24 20BR/LB 2 SENSOR GROUND K900 20DB/DG 3 5 VOLT SUPPLY F855 20PK/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7801 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7802 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7803 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7804 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (5.7L) Pin Description Circuit 1 5 VOLT SUPPLY F855 20PK/YL 2 SENSOR GROUND K900 20DB/DG 3 CKP SIGNAL K24 20BR/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7805 Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7806 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7807 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7808 Connector: Name : SENSOR-CRANKSHAFT POSITION Color : BLACK # of pins : 3 Qualifier : (DIESEL) Pin Description Circuit 1 5 VOLT SUPPLY K853 18DB/BR Pin Description Circuit 1 5 VOLT SUPPLY K824 18DB/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7809 2 CKP SENSOR GROUND K975 18BR/OR 2 CKP SENSOR GROUND K925 18BR/OR 3 CKP SIGNAL K24 18BR/LB Component Location - 5 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7810 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7811 Component Location - 13 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 7812 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The Crankshaft Position Sensor (CKP) on the diesel engine is attached at the front / left side of the engine next to the engine harmonic balancer (crankshaft damper). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 7815 Crankshaft Position Sensor: Description and Operation Operation OPERATION The Crankshaft Position Sensor (CKP) (5) is the primary engine speed indicator for the engine after the engine is running. The CKP contains a hall effect device. A rotating, notched target wheel (tonewheel) (3) for the CKP is attached to the engine harmonic balancer (2). This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CKP. When the leading edge of the tonewheel notch passes the tip of the CKP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CKP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The Camshaft Position Sensor (CMP) also provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses this CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal Crankshaft Position Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle 2. Disconnect electrical connector (4) at CKP sensor. 3. Remove 1 sensor mounting bolt (3). 4. Remove CKP sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 7818 Crankshaft Position Sensor: Service and Repair Installation INSTALLATION 1. Position and install CKP sensor (5) to engine. 2. Install 1 sensor mounting bolt and tighten to 9 Nm (80 in. lbs.) torque. 3. Install electrical connector (4) to CKP sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal Ignition Switch Lock Cylinder: Service and Repair Removal REMOVAL The ignition key must be in the key cylinder (1) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at the underside of the key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal > Page 7824 Ignition Switch Lock Cylinder: Service and Repair Installation INSTALLATION The ignition key must be in the key cylinder (3) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (3) with the ignition switch (1). 2. Push the key cylinder (3) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Description Knock Sensor: Description and Operation Description DESCRIPTION Two knock sensors are bolted into the cylinder block under the intake manifold 3.7L, 4.7L & 8.3L. Two knock sensors are also used with the 5.7L. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Description > Page 7829 Knock Sensor: Description and Operation Operation OPERATION Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Glow Plug System > Wait To Start Light > Component Information > Description and Operation > Description Wait To Start Light: Description and Operation Description DESCRIPTION A wait-to-start indicator is only found in the instrument clusters for vehicles equipped with an optional diesel engine. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The wait-to-start indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Diesel Preheat in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The wait-to-start indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Glow Plug System > Wait To Start Light > Component Information > Description and Operation > Description > Page 7835 Wait To Start Light: Description and Operation Operation OPERATION The wait-to-start indicator gives an indication to the vehicle operator when the air temperature within the diesel engine intake manifold is too cool for efficient and reliable engine starting, and that the intake air heater grids are energized in their pre-heat operating mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Engine Control Module (ECM) over the Controller Area Network (CAN) data bus. The wait-to-start indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the wait-to-start indicator for the following reasons: - Wait-To-Start Indicator Lamp-On Message - Each time the cluster receives an electronic wait-to-start indicator lamp-ON message from the ECM indicating that the air temperature within the intake manifold is too cool for efficient and reliable engine starting, the wait-to-start indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message, until the ECM detects that the engine is running or until the ignition switch is turned to the OFF position, whichever occurs first. Actuator Test - Each time the cluster is put through the actuator test, the wait-to-start indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The ECM continually monitors the engine intake air temperature sensor to determine when the intake air heater grids should be energized in their pre-heat operating mode. The ECM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the wait-to-start indicator or the instrument cluster circuitry that controls the indicator, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the engine intake air temperature sensor, the intake air heater grid control circuits, the ECM, the EMIC, the CAN data bus or the electronic communication related to wait-to-start indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Description Overdrive Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Description > Page 7843 Overdrive Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > Removal Overdrive Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > Removal > Page 7846 Overdrive Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid Pressure Regulating Solenoid: Locations Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7851 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7852 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7853 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7854 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7855 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7856 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7857 Pressure Regulating Solenoid: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7858 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid Pressure Regulating Solenoid: Diagrams Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7861 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7862 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7863 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7864 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7865 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7866 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7867 Pressure Regulating Solenoid: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7868 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Description Pressure Regulating Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Description > Page 7871 Pressure Regulating Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Removal Pressure Regulating Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Removal > Page 7874 Pressure Regulating Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Component ID: 440 Component : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Connector: Name : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Color : BLACK # of pins : 2 Pin Description Circuit 1 BTSI SOLENOID CONTROL K32 18DB/YL 2 GROUND Z101 18BK/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7878 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7879 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7880 Shift Interlock Solenoid: Diagrams Component ID: 440 Component : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Connector: Name : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Color : BLACK # of pins : 2 Pin Description Circuit 1 BTSI SOLENOID CONTROL K32 18DB/YL 2 GROUND Z101 18BK/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7881 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7882 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid Shift Solenoid: Locations Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7887 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7888 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7889 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7890 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7891 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7892 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7893 Shift Solenoid: Locations Assembly-Transmission Solenoid/Pressure Switch Component ID: 17 Component : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH Color : LT. BROWN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 OD SOLENOID CONTROL T60 20YL/GY 2 UD CONTROL T59 20YL/LB 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 2-4 SOLENOID CONTROL T19 18YL/DB 5 2-4 PRESSURE SWITCH SENSE T47 18YL/DG 6 OD PRESSURE SIGNAL T9 20DG/TN 7 L/R CONTROL T20 20DG/WT 8-9-10 L/R PRESSURE SIGNAL T50 20YL/TN Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7894 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7895 Shift Solenoid: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7896 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid Shift Solenoid: Diagrams Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7899 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7900 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7901 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7902 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7903 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7904 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7905 Shift Solenoid: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7906 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation > Description Shift Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation > Description > Page 7909 Shift Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Removal Shift Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Removal > Page 7912 Shift Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Description and Operation Throttle Valve Solenoid: Description and Operation DESCRIPTION On vehicles equipped with a Cummins diesel engine, the transmission throttle valve cable has been replace by the transmission throttle valve actuator (TTVA). The TTVA consists of an electric DC motor, two potentiometers, and a gear drive system. The TTVA is mechanically connected to the transmission throttle valve in the valve body by the "D" shaped opening in the bottom of the TTVA shaft. Changes in the TTVA position are therefore transferred to the throttle valve and cause changes in the transmission throttle pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Description and Operation > Page 7916 Throttle Valve Solenoid: Adjustments ADJUSTMENT The Transmission Throttle Valve Actuator (TTVA) does not require any mechanical adjustments. All changes in throttle valve position are controlled by the Engine Control Module (ECM). The TTVA does require an initialization period after the actuator has been removed or replaced. After the actuator has been removed or replaced, move the ignition to the ON position for thirty (30) seconds. This will allow the ECM sufficient time to perform the internal calibration procedures to learn the TTVA's current "zero" position. Once this is done, check the ECM for diagnostic trouble codes (DTCs). If no DTCs are set relating to the TTVA, the TTVA is fully calibrated and ready for use. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Service and Repair > Removal Throttle Valve Solenoid: Service and Repair Removal REMOVAL 1. Remove the bolts (2) holding the transmission throttle valve actuator (TTVA) (1) to the transmission case. 2. Allow the TTVA (1) to rotate clockwise away from the transmission. 3. Remove the wiring connector (2) from the TTVA (1). 4. Lift the TTVA (1) straight upward and off the throttle valve shaft (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Service and Repair > Removal > Page 7919 Throttle Valve Solenoid: Service and Repair Installation INSTALLATION 1. Position the transmission throttle valve actuator (TTVA) (1) over the throttle valve shaft (3). 2. Align the D-shaped opening in the bottom of the TTVA to the throttle valve shaft and install the TTVA onto the shaft. 3. Install the wiring connector (2) to the TTVA (1). 4. Rotate the TTVA (1) to the transmission case and install the bolts (2) to hold the TTVA to the transmission. 5. Tighten the bolts to 8.5 Nm (75 in.lbs.). 6. Initialize the TTVA. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal Actuator: Service and Repair Removal REMOVAL 1. Remove actuator wiring connector. 2. Remove actuator (1) bolts (2). 3. Remove actuator (1) from disconnect pocket (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal > Page 7925 Actuator: Service and Repair Installation INSTALLATION 1. Clean actuator (1) sealing surface and install new gasket (2) if necessary. 2. Align actuator shift fork (1) with disconnect collar (2) and install actuator on disconnect pocket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal > Page 7926 3. Install actuator (1) bolts (2) and tighten to 27 Nm (20 ft. lbs.). 4. Install disconnect actuator wiring connector. 5. Verify differential fluid level and add fluid if necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front Solenoid: Locations Module-Axle Disconnect-Front Component ID: 200 Component : MODULE-AXLE DISCONNECT-FRONT Connector: Name : MODULE-AXLE DISCONNECT-FRONT Color : DK. GRAY # of pins : 4 Qualifier : (LD 4WD) Pin Description Circuit 1 GROUND Z906 20BK 2 FRONT AXLE LOCK CONTROL G304 20VT/DB 3 FUSED B(+) A880 20DB/RD 4 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 35 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 7931 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 7932 Solenoid: Locations Solenoid-Locker-Front Component ID: 442 Component : SOLENOID-LOCKER-FRONT Connector: Name : SOLENOID-LOCKER-FRONT Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 FRONT LOCKER SOURCE T520 16YL/OR 2 LOCKER SENSOR SUPPLY T521 18YL/BK 3 FRONT LOCKER SENSOR SENSE T522 18YL/LB 4 FRONT LOCKER RETURN T524 16YL/LG Component Location - 36 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 7933 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 7934 Solenoid: Locations Solenoid-Locker-Rear Component ID: 443 Component : SOLENOID-LOCKER-REAR Connector: Name : SOLENOID-LOCKER-REAR Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 REAR LOCKER SOURCE T526 16YL/WT 2 LOCKER SENSOR SUPPLY T523 18YL/BK 3 REAR LOCKER SENSOR SENSE T527 18YL/TN 4 REAR LOCKER RETURN T528 16YL/GY Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 7935 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front Solenoid: Diagrams Module-Axle Disconnect-Front Component ID: 200 Component : MODULE-AXLE DISCONNECT-FRONT Connector: Name : MODULE-AXLE DISCONNECT-FRONT Color : DK. GRAY # of pins : 4 Qualifier : (LD 4WD) Pin Description Circuit 1 GROUND Z906 20BK 2 FRONT AXLE LOCK CONTROL G304 20VT/DB 3 FUSED B(+) A880 20DB/RD 4 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 35 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 7938 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 7939 Solenoid: Diagrams Solenoid-Locker-Front Component ID: 442 Component : SOLENOID-LOCKER-FRONT Connector: Name : SOLENOID-LOCKER-FRONT Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 FRONT LOCKER SOURCE T520 16YL/OR 2 LOCKER SENSOR SUPPLY T521 18YL/BK 3 FRONT LOCKER SENSOR SENSE T522 18YL/LB 4 FRONT LOCKER RETURN T524 16YL/LG Component Location - 36 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 7940 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 7941 Solenoid: Diagrams Solenoid-Locker-Rear Component ID: 443 Component : SOLENOID-LOCKER-REAR Connector: Name : SOLENOID-LOCKER-REAR Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 REAR LOCKER SOURCE T526 16YL/WT 2 LOCKER SENSOR SUPPLY T523 18YL/BK 3 REAR LOCKER SENSOR SENSE T527 18YL/TN 4 REAR LOCKER RETURN T528 16YL/GY Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 7942 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations Transfer Case Actuator: Locations Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7947 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7948 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7949 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7950 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7951 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7952 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7953 Transfer Case Actuator: Diagrams Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7954 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7955 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7956 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7957 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7958 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7959 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case Transfer Case Actuator: Description and Operation NV243 Transfer Case Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 7962 torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 7963 Transfer Case Actuator: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 7964 Transfer Case Actuator: Description and Operation NV246 Transfer Case Description DESCRIPTION The shift motor consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Front Control Module (FCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 7965 Transfer Case Actuator: Description and Operation NV273 Transfer Case Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case Transfer Case Actuator: Service and Repair NV243 Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. Installation INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 7968 Transfer Case Actuator: Service and Repair NV244 GENII Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. Installation INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 7969 Transfer Case Actuator: Service and Repair NV246 Transfer Case Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Remove the front propeller shaft. 3. Disengage the wiring connectors from the shift motor and mode sensor. 4. Remove the bolts (1) holding the shift motor and mode sensor assembly (2) onto the transfer case. 5. Separate the shift motor and mode sensor assembly (1) from the transfer case. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 7970 6. Remove the shift motor isolator (1) from the transfer case (2). Installation INSTALLATION 1. Install the shift motor isolator (1) onto the transfer case (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 7971 NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Install the shift motor and mode sensor assembly (1) onto the transfer case. CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 3. Install the bolts (1) to hold the shift motor and mode sensor assembly (2) onto the transfer case. Tighten the bolts to 23.5 Nm (17 ft.lbs.). 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Install the front propeller shaft. 6. Refill the transfer case as necessary with the correct fluid for the application. 7. Lower vehicle and verify transfer case operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 7972 Transfer Case Actuator: Service and Repair NV273 Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. Installation INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator Overdrive Indicator Lamp: Description and Operation Overdrive Off Indicator Description DESCRIPTION An overdrive off indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The overdrive off indicator consists of a stencil-like cutout of the text O/D OFF in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the overdrive off indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The overdrive off indicator is serviced as a unit with the instrument cluster. Operation OPERATION The overdrive off indicator gives an indication to the vehicle operator when the overdrive-OFF position of the tow/haul switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The overdrive off indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the overdrive off indicator for the following reasons: - Overdrive Off Indicator Lamp-On Message - Each time the cluster receives an electronic overdrive off indicator lamp-ON message from the PCM indicating that the overdrive-OFF position of the tow/haul switch has been selected, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the overdrive off indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the overdrive off indicator or the instrument cluster circuitry that controls the indicator, refer to Instrument Cluster/Carrier Testing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 7979 For proper diagnosis of the transmission control system, the PCM, the EMIC, the CAN data bus or the electronic communication related to overdrive off indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 7980 Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator Description DESCRIPTION A tow/haul indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The tow/haul indicator consists of a stencil-like cutout of the text TOW/HAUL in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the tow/haul indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The tow/haul indicator is serviced as a unit with the instrument cluster. Operation OPERATION The tow/haul indicator gives an indication to the vehicle operator when the tow/haul function of the tow/haul switch has been selected, revising the shift schedule of the electronically controlled automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The tow/haul indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the tow/haul indicator for the following reasons: - Tow/Haul Indicator Lamp-On Message - Each time the cluster receives an electronic tow/haul indicator lamp-ON message from the PCM indicating that the tow/haul shift schedule has been selected, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the tow/haul indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the tow/haul indicator or the instrument cluster circuitry that controls the indicator refer to Instrument Cluster / Carrier testing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 7981 For proper diagnosis of the transmission control system, the PCM, the EMIC, the CAN data bus or the electronic communication related to tow/haul indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description Temperature Warning Indicator - A/T: Description and Operation Description DESCRIPTION A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The transmission over-temperature indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Transmission Temperature in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The transmission over-temperature indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description > Page 7986 Temperature Warning Indicator - A/T: Description and Operation Operation OPERATION The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received over the Controller Area Network (CAN) data bus from the Powertrain Control Module (PCM). The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Indicator Lamp-On Message - Each time the cluster receives an electronic trans over-temp indicator lamp-ON message from the PCM indicating that the transmission fluid temperature is 135° C (275° F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the indicator is cycled OFF and then ON again by the appropriate lamp-ON and lamp-OFF messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the transmission over-temperature indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the instrument cluster illuminates the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission or the transmission cooling system are being overloaded, or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED,refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transmission temperature sensor, the PCM, the EMIC, the CAN data bus or the electronic communication related to transmission over-temperature indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description Four Wheel Drive Indicator Lamp: Description and Operation Description 4WD Auto Indicator 4WD AUTO INDICATOR A 4WD auto indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD auto indicator is located on the right side of the instrument cluster, to the right of the oil pressure gauge. The 4WD auto indicator consists of a stencil-like cutout of the text 4WD AUTO in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD auto indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD auto indicator is serviced as a unit with the instrument cluster. 4WD Indicator 4WD INDICATOR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 7992 A 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional four-wheel drive system, this indicator is electronically disabled. The 4WD indicator is located on the right side of the instrument cluster, to the right of the oil pressure gauge. The 4WD indicator consists of a stencil-like cutout of the text 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD indicator is serviced as a unit with the instrument cluster. 4WD Low Indicator 4WD LOW INDICATOR A 4WD low indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD low indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The 4WD low indicator consists of a stencil-like cutout of the text 4WD LOW in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD low indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD low indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 7993 Four Wheel Drive Indicator Lamp: Description and Operation Operation 4WD Auto Indicator 4WD AUTO INDICATOR The 4WD auto indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD auto mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD auto indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD auto indicator for the following reasons: - 4WD Auto Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD auto indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD auto indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD auto mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD auto indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD auto indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. 4WD Indicator 4WD INDICATOR The 4WD indicator gives an indication to the vehicle operator when the transfer case has been shifted into a 4WD mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD indicator for the following reasons: - 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly or the manual transfer case through the transfer case switch to determine when the 4WD mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the transfer case switch, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. 4WD Low Indicator 4WD LOW INDICATOR The 4WD low indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD low mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD low indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 7994 indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD low indicator for the following reasons: - 4WD Low Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD low indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD low indicator will be turned ON, then OFF again during the LED portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD low mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD low indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD low indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Description Malfunction Indicator Lamp - Transfer Case: Description and Operation Description DESCRIPTION A service 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The service 4WD indicator consists of a stencil-like cutout of the text SVC 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The service 4WD indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Description > Page 7999 Malfunction Indicator Lamp - Transfer Case: Description and Operation Operation OPERATION The service 4WD indicator gives an indication to the vehicle operator when the Totally Integrated Power Module (TIPM) has recorded a Diagnostic Trouble Code (DTC) for an electronic transfer case circuit or component malfunction. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the TIPM over the Controller Area Network (CAN) data bus. The service 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the service 4WD indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the service 4WD indicator is illuminated for about two seconds as a bulb test. - Service 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic service 4WD indicator lamp-ON message from the TIPM, the service 4WD indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the TIPM for 10 seconds the service 4WD indicator is illuminated by the cluster to indicate a loss of TIPM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the TIPM. - Actuator Test - Each time the cluster is put through the actuator test, the service 4WD indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case control circuits and transfer case shift motor/mode sensor assembly to determine the condition of the system. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the service 4WD indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the TIPM, the EMIC, the CAN data bus or the electronic communication related to service 4WD indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set Control Module: Customer Interest Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 8010 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 8011 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: Customer Interest A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 8016 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 8017 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set Control Module: Customer Interest A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8022 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8023 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8024 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8025 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set Control Module: All Technical Service Bulletins Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 8031 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 8032 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: All Technical Service Bulletins A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 8037 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 8038 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set Control Module: All Technical Service Bulletins A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8043 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8044 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8045 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8046 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8047 Control Module: Locations Component ID: 214 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2-3 POWER TAKEOFF RELAY ENABLE K427 18OR/LG 4-5 PRESSURE SIGNAL 4 T803 20DG/BR 6 PRESSURE SIGNAL 1 T800 20DG/BR 7-8-9-10 - 11 PRESSURE SIGNAL 5 T804 20YL/DB 12 PRESSURE SIGNAL 3 T802 20DG/PK 13 - 14 - 15 - 16 PRESSURE SIGNAL 6 T805 20DG/OR 17 PRESSURE SIGNAL 2 T801 20DG/RD Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8048 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Description Circuit 1 8 VOLT SUPPLY T72 20YL/DB 2 OUTPUT SPEED SIGNAL T14 20DG/BR 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8049 5-6-7 FUSED B(+) A104 20YL/RD 8 GROUND Z133 18BK/LG 9-10 - 11 - 12 - 13 - 14 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 15 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 16 TCC TEMPERATURE SIGNAL T819 20YL/VT 17 GROUND Z133 18BK/LG 18 - 19 SHIFT 4 CONTROL T811 20DG/LB 20 CAN C BUS (+) D65 20WT/LG 21 CAN C BUS (-) D64 20WT/LB 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8050 Pin Description Circuit 1 SHIFT 1 CONTROL T808 20DG/GY 2-3 SHIFT 3 CONTROL T810 20DG/DB 4-5 LINEAR 3 CONTROL T817 20YL/BR 6 LINEAR 1 GROUND T812 20DG/TN 7 LINEAR 1 CONTROL T813 20DG/LG 8 LINEAR 2 CONTROL T815 20YL/RD 9 LINEAR 2 GROUND T814 20YL/BR 10 PRESSURE SIGNAL 7 T806 20DG/VT 11 - 12 - 13 - 14 - - 15 LINEAR 3 GROUND T816 20YL/PK 16 TRS 1 SIGNAL T828 20DG/DB 17 TRS T42 SIGNAL T42 20DG/YL 18 TRS T3 SIGNAL T3 20DG/DB 19 TRS DRIVE SIGNAL T827 20DG/LB 20 TRS PARK SIGNAL T824 20YL/DB 21 TRS REVERSE SIGNAL T826 20DG/DB 22 SHIFT 2 CONTROL T809 20DG/YL 23 - 24 - 25 - 26 PRESSURE SIGNAL 8 T807 20DG/WT 27 - 28 TEMPERATURE SENSOR GROUND T820 20YL/WT 29 TRS NEUTRAL SIGNAL T825 20DG/YL 30 LINEAR 4 CONTROL T821 20YL/GY 31 LINEAR 4 GROUND T818 20YL/OR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8051 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8052 Control Module: Diagrams Component ID: 214 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2-3 POWER TAKEOFF RELAY ENABLE K427 18OR/LG 4-5 PRESSURE SIGNAL 4 T803 20DG/BR 6 PRESSURE SIGNAL 1 T800 20DG/BR 7-8-9-10 - 11 PRESSURE SIGNAL 5 T804 20YL/DB 12 PRESSURE SIGNAL 3 T802 20DG/PK 13 - 14 - 15 - 16 PRESSURE SIGNAL 6 T805 20DG/OR 17 PRESSURE SIGNAL 2 T801 20DG/RD Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8053 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Description Circuit 1 8 VOLT SUPPLY T72 20YL/DB 2 OUTPUT SPEED SIGNAL T14 20DG/BR 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8054 5-6-7 FUSED B(+) A104 20YL/RD 8 GROUND Z133 18BK/LG 9-10 - 11 - 12 - 13 - 14 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 15 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 16 TCC TEMPERATURE SIGNAL T819 20YL/VT 17 GROUND Z133 18BK/LG 18 - 19 SHIFT 4 CONTROL T811 20DG/LB 20 CAN C BUS (+) D65 20WT/LG 21 CAN C BUS (-) D64 20WT/LB 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8055 Pin Description Circuit 1 SHIFT 1 CONTROL T808 20DG/GY 2-3 SHIFT 3 CONTROL T810 20DG/DB 4-5 LINEAR 3 CONTROL T817 20YL/BR 6 LINEAR 1 GROUND T812 20DG/TN 7 LINEAR 1 CONTROL T813 20DG/LG 8 LINEAR 2 CONTROL T815 20YL/RD 9 LINEAR 2 GROUND T814 20YL/BR 10 PRESSURE SIGNAL 7 T806 20DG/VT 11 - 12 - 13 - 14 - - 15 LINEAR 3 GROUND T816 20YL/PK 16 TRS 1 SIGNAL T828 20DG/DB 17 TRS T42 SIGNAL T42 20DG/YL 18 TRS T3 SIGNAL T3 20DG/DB 19 TRS DRIVE SIGNAL T827 20DG/LB 20 TRS PARK SIGNAL T824 20YL/DB 21 TRS REVERSE SIGNAL T826 20DG/DB 22 SHIFT 2 CONTROL T809 20DG/YL 23 - 24 - 25 - 26 PRESSURE SIGNAL 8 T807 20DG/WT 27 - 28 TEMPERATURE SENSOR GROUND T820 20YL/WT 29 TRS NEUTRAL SIGNAL T825 20DG/YL 30 LINEAR 4 CONTROL T821 20YL/GY 31 LINEAR 4 GROUND T818 20YL/OR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8056 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description Control Module: Description and Operation Description DESCRIPTION On gasoline vehicles the Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). 68RFE TCM LOCATION Vehicles equipped 68RFE transmission and a 6.7L Diesel engine, the TCM is housed in the NGC4 controller utilizing only the C1 and C4 connectors (TCM only). The controller is located at the rear of the engine compartment, near the right inner fender. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 8059 AS68RC TCM LOCATION On Cab Chassis models equipped with the AS68RC transmission the Transmission Control Module (TCM) has three electrical connectors and is located in the passenger compartment underneath of the left side of the dash panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 8060 Control Module: Description and Operation Operation OPERATION RLE and RFE TRANSMISSIONS The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) (if equipped) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 8061 An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 8062 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 8063 SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 8064 AISIN AS68RC TRANSMISSION The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Speed Sensor - Output Speed Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 8065 - Manifold Pressure - Throttle position - Torque Reduction Confirmation - Engine Coolant Temperature - Exhaust Brake Status (if equipped) - PTO Request (if equipped) - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Exhaust Brake Cut Request (if equipped). - Solenoids. - Torque Reduction Request. Some examples of TCM .indirect outputs are: - Transmission Temperature (to PCM). - PRNDL Position (to cluster/CCN). - PTO Status. In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI). - Storing and selecting appropriate Shift Schedules. - System self-diagnostics. - Diagnostic capabilities (with scan tool). Clutch filling time is continuously maintained when the vehicle is running. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8070 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8071 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8072 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8073 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8074 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8075 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8076 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8077 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8078 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8079 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8080 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8081 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8082 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8083 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8084 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8085 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8086 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8087 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8088 Transmission Control System Relay: Connector Views Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > AS68RC Automatic Transmission Transmission Control System Relay: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION AS68RC Automatic Transmission NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. The relay is supplied fused B+ voltage, energized by the TIPM, and is used to supply power to the TCM when the transmission is in normal operating mode. Operation OPERATION The TIPM energizes the transmission control relay. When the relay is "off", no power is supplied to the TCM and the transmission will not operate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Control Module: Locations Component ID: 204 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 LOCKER SENSOR SUPPLY T521 20YL/BK A2 LOCKER SWITCH SUPPLY T537 20YL/LG A3 LOCKER SENSOR SUPPLY T523 20YL/BK A4 - A5 - A6 CAN C BUS (+) D65 20WT/LG A7 CAN C BUS (-) D64 20WT/LB A8 REAR LOCKER SENSOR SENSE T527 20YL/TN A9 FRONT LOCKER SENSOR SENSE T522 20YL/LB A10 LOCKER SWITCH SENSE T535 20YL/BR A11 - A12 - A13 - A14 - B FUSED B(+) A121 14RD/YL B1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG B2 SWITCH SUPPLY T536 20YL/WT B3 - B4 - B5 STABILIZER BAR SWITCH SENSE T531 20YL/TN B6 LOCKER OPEN ILLUMINATION SENSE T532 20YL/GY B7 LOCKER REAR ILLUMINATION SENSE T533 20YL/LB B8 LOCKER FR/RR ILLUMINATION SENSE T534 20YL B9 STABILIZER BAR DISENGAGE ILLUMINATION SENSE T530 20YL/DG B10 STABILIZER BAR ENGAGE ILLUMINATION SENSE T529 20YL/LG B11 - B12 - B13 - B14 - C FRONT LOCKER SOURCE T520 16YL/OR C1 - C2 - C3 - C4 - C5 - - Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 8095 C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - D REAR LOCKER SOURCE T526 16YL/WT E GROUND Z935 16BK F GROUND Z935 16BK G FRONT LOCKER RETURN T524 16YL/LG H REAR LOCKER RETURN T528 16YL/GY Component Location - 29 Component Location - 28 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 8096 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 8097 Control Module: Diagrams Component ID: 204 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 LOCKER SENSOR SUPPLY T521 20YL/BK A2 LOCKER SWITCH SUPPLY T537 20YL/LG A3 LOCKER SENSOR SUPPLY T523 20YL/BK A4 - A5 - A6 CAN C BUS (+) D65 20WT/LG A7 CAN C BUS (-) D64 20WT/LB A8 REAR LOCKER SENSOR SENSE T527 20YL/TN A9 FRONT LOCKER SENSOR SENSE T522 20YL/LB A10 LOCKER SWITCH SENSE T535 20YL/BR A11 - A12 - A13 - A14 - B FUSED B(+) A121 14RD/YL B1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG B2 SWITCH SUPPLY T536 20YL/WT B3 - B4 - B5 STABILIZER BAR SWITCH SENSE T531 20YL/TN B6 LOCKER OPEN ILLUMINATION SENSE T532 20YL/GY B7 LOCKER REAR ILLUMINATION SENSE T533 20YL/LB B8 LOCKER FR/RR ILLUMINATION SENSE T534 20YL B9 STABILIZER BAR DISENGAGE ILLUMINATION SENSE T530 20YL/DG B10 STABILIZER BAR ENGAGE ILLUMINATION SENSE T529 20YL/LG B11 - B12 - B13 - B14 - C FRONT LOCKER SOURCE T520 16YL/OR C1 - C2 - C3 - C4 - C5 - - Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 8098 C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - D REAR LOCKER SOURCE T526 16YL/WT E GROUND Z935 16BK F GROUND Z935 16BK G FRONT LOCKER RETURN T524 16YL/LG H REAR LOCKER RETURN T528 16YL/GY Component Location - 29 Component Location - 28 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 8099 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description Control Module: Description and Operation Description DESCRIPTION The Transfer Case Control Module (TCCM) functionality now resides in the Totally Integrated Power Module (TIPM), refer to the TIPM information for location. The TIPM controls the 4X4 transfer case shift functions via the actuation of a shift motor and utilizing the feedback of a mode sensor assembly. Communication is via the CAN bus. Inputs include user selectable 4X4 modes that include 2WD, AWD, 4HI, 4LO, and Neutral (selections vary with the specific transfer case). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 8102 Control Module: Description and Operation Operation OPERATION The Transfer Case Control Module (TCCM) functionality in the Totally Integrated Power Module (TIPM) utilizes the input from the transfer case mounted mode sensor, the instrument panel mounted selector switch, and the following information from the vehicle's CAN bus to determine if a shift is allowed. - Engine RPM and Vehicle Speed - Diagnostic Requests - Manual Transmission and Brake Applied - PRNDL - Ignition Status - ABS Messages Once the TIP determines that a requested shift is allowed, it actuates the bi-directional shift motor as necessary to achieve the desired transfer case operating mode. The TIPM also monitors the mode sensor while controlling the shift motor to determine the status of the shift attempt. Several items can cause the requested shift not to be completed. If the TIPM has recognized a fault (DTC) of some variety, it will begin operation in one of four Functionality Levels. These levels are: - Level Zero - Normal Operation. - Level One - Only Mode Shifts Are Allowed. - Level Two - Only Mode Shifts and Shifts Into LOW Are Allowed (No Neutral Shifts Are Allowed). - Level Three - No Shifts Are Allowed The TIPM can also be operating in one of three possible power modes. These power modes are: - Full Power Mode is the normal operational mode of the module. This mode is achieved by normal CAN bus traffic being present and the ignition being in the RUN position. Reduced Power Mode will be entered when the ignition has been powered off. In this state, the module will shut down power supplied to external devices, and to electronic interface inputs and outputs. From this state the module can enter either Sleep Mode or Full Power Mode. To enter this mode, the module must receive an ignition message denoting that the ignition is off, or not receive any messages for 5 ± 0.5 seconds. To exit this mode, the module must receive one ignition message that denotes that the ignition is in the RUN position. - Sleep Mode will be entered, from the Reduced Power Mode, when no CAN traffic has been sensed for 20 ± 1 seconds. If during Sleep Mode the module detects CAN bus traffic, it will revert to the Reduced Power mode while monitoring for ignition messages. It will remain in this state as long as there is traffic other than run or start messages, and will return to Sleep mode if the bus goes without traffic for 20 ± 1 seconds. SHIFT REQUIREMENTS If the TIPM is in full power mode and at functionality level zero, it uses the following criteria to determine if a shift is allowed. If any of the driver controllable conditions are not met once the shift request is recognized, the TIPM will solidly illuminate the source position's LED and flash the desired position's LED for all shifts except NEUTRAL. The NEUTRAL shift LED strategy will be discussed later. Mode shifts will be allowed regardless of transmission gear or vehicle speed, whenever the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - A change in the Selector switch state indicates that a mode shift has been requested. - A valid mode sensor signal is being sensed by the TIPM. - Proper transmit/receive messages are occurring on the CAN bus. - Ignition key switch is in the RUN position. Range shifts will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - A change in the Selector Switch state indicating a range shift has been requested. - Transmission in NEUTRAL signal must be recognized for at least 1.5 seconds ± 100 msec. (Automatic transmissions only) - Proper transmit/receive messages are occurring on the CAN bus. - Clutch signal is recognized for 500 msec ± 50 msec (Manual transmissions only). - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position. - A valid mode sensor signal is being sensed by the TIPM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 8103 A shift into transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 4.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus. (Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the CAN bus. - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position, engine off. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TIPM. A shift out of transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 1.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus.(Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the CAN bus. - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TIPM. SHIFT SEQUENCES Once all the driver controllable conditions for the requested shift have been met, the TIPM begins a shift timer with a maximum duration of 1 second per 'D' channel transition. If the shift timer expires before the TIPM recognizes to correct mode sensor code, the shift is considered to have been blocked. The blocked shift will increment the blocked shift counter by one. The TIPM strategy for handling blocked shifts will be described later. The process the TIPM performs for the various shifts will be described first. RANGE AND MODE SHIFTS The process for performing all the range and mode shifts are the same. The following steps describe the process. - Allow time for Selector Switch debounce; 250 msec ± 50 msec. - Extinguish the source gear's LED while flashing desired transfer case position's LED. - Engage the shift motor for a maximum of 1 second ± 100 msec per 'D' channel transition in the destination gear's direction while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Solidly illuminate the selected gear's LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds ± 100 msec. per 'D' channel. The TIPM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. The exception to the preceding sequence is when a shift from 4L to 2WD/AWD is requested. If 2WD/AWD is requested from the 4L position, the transfer case is first driven to the 4H position. If the 4H position is reached, the transfer case is then driven back to the 2WD/AWD position and the shift is considered complete. If the transfer case does not reach any the 4H position, but is in the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is also considered complete. SHIFT OUT OF NEUTRAL The following steps describe the process for a shift out of NEUTRAL. - Extinguish the Neutral LED. - Engage the shift motor for a maximum of 1 second ± 100 msec toward the transfer case 4H mode position while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Extinguish the Neutral LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds 100 msec. The Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 8104 TIPM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. - When the Neutral button is released, if the 4H position is the desired position, the shift is complete. Illuminate the 4H LED. - Otherwise when the Neutral button is released, if all of the shift requirements are being met then engage the shift motor towards the desired position for 1 second ± 100 msec per 'D' channel. (if requirements for shifting are not met, illuminate the 4H LED and flash the destination LED as an indication to the driver that all of the driver controllable shift conditions are not being met). If this requires another range or mode shift, begin the range/mode shift process. - If the desired mode sensor code is not received after the shift timer expires (i.e. a blocked or other condition exists), refer to Blocked Shift Strategy. BLOCKED SHIFT STRATEGY When a shift is commanded, the shift motor will be driven towards its destination position, except in the case of shifting out of Neutral if 4L was selected (the transfer case will shift to the 4H position first, before proceeding to 4L). If the shift is blocked on the way to the destination, the TIPM may attempt to drive the motor back to the original position. This process will be allowed to occur 5 times. If the transfer case has reached a non-NEUTRAL 'D' channel during the shift re-attempts, the LED for the achieved gear position is illuminated and the shift attempts are stopped. To re-attempt the desired shift, the selector switch will need to be rotated to the current position until the switch debounce timer expires then a shift will need to be requested again. At the end of the 5th blocked attempt, the shift motor is driven towards the last known 'D' channel position. If this motor drive allows the transfer case to reach the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is considered complete and the shift attempts are ended. If the mode sensor is in the NEUTRAL region at the expiration of the shift timer, the TIPM will continue to make the shift attempts according to the blocked shift strategy independent of whether or not the driver controlled conditions are met. For shifts from NEUTRAL, if all 5 attempts fail to reach the desired position (which by default is 4H), the motor will be driven to stall in the direction of 4H or 4L, depending on the achieved position. If the transfer case has reached the 2WD/AWD or 4L between gear position nearest the NEUTRAL positions and the shift conditions are no longer being met, the transfer case will be driven toward the corresponding 'D' channel. Otherwise, the transfer case will be driven in the direction opposite the last attempt with the desired target being 4H or 4L. If the transfer case reaches the 2WD/AWD 'D' channel when being driven in the 4H direction, then one final 1.0 second drive toward 4H is attempted. If the transfer case then reaches any of the 4H positions, the shift is considered complete and the 4H LED is illuminated. If the transfer case is still the 2WD/AWD position, the shift is considered complete and the 2WD/AWD LED is illuminated. NOTE: If after the 5th blocked shift and reversal attempt, if the transfer case position is in the NEUTRAL region, shift attempts will continue until a non-NEUTRAL 'D' channel is reached. SHIFT REVERSAL TARGETS If the shift timer expires (1 second per 'D' channel) and the transfer case has not reached the desired position, all shifts will attempt to return to their original position with the exceptions of: - If the intended shift is going to the High rail from Low and can't make it, but it can make the 2WD/AWD position, the motor stops at that position. The TIPM will not attempt to cross back over NEUTRAL if it does not have to. This means that there was a block on the first attempt to go to 4H and the transfer case has made it through NEUTRAL to a known good position, then the motor will go back only to the 2WD/4WD position and execute the remainder of the attempts from there. - For shifts out of NEUTRAL, any time a shift is commanded out of NEUTRAL, the system needs to get out. The TIPM should never go to NEUTRAL unless the driver is commanding it and all required conditions are being met ENCODER DRIFT CORRECTION Whenever a shift is completed, the TIPM stores the position in memory as the transfer case's intended position. The TIPM continuously monitors the mode sensor and if the mode sensor drifts toward into a NEUTRAL region sensor position for 2.0 seconds, the TIPM will perform a motor drive to correct the drift. The transfer case will be driven toward the intended position for 1.0 seconds ± 100 msec. The TIPM will wait for 2.0 seconds ± 50 msec. and repeat the attempt to shift to the desired position. This will continue until the intended position is reached. SHIFT MOTOR BRAKING Two modes of shift motor braking are employed to improve shift performance, static and dynamic. Static shift motor braking is utilized under the following conditions: - Whenever the transfer case is in the 2WD/AWD or 4L 'D' channel position. - Whenever an invalid mode sensor code is present. Static motor braking is achieved by applying +12V on both shift motor wires. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 8105 NOTE: Static Shift Motor Braking is independent of ignition key position. SHIFT ATTEMPT LIMIT To protect the transfer case system, the TIPM will impose a limit on the number of shifts that can occur over a calibrated time period. The system will monitor the number of 'D' channel segment transitions that occur in any 30 second time period. If the number of segment transitions is 30 or greater, the system will go into a default mode. The default mode of operation for shifting is that the number of allowed 'D' channel transitions permitted to occur will be 3 over each 15 second ± 100 msec calibrated window of time. After 5 minutes ± 100 msec, the motor can be assumed to have cooled down and the system will revert to normal operation. The following rules also apply to the shift limit: - The attempt limit will not prevent shifts coming out of NEUTRAL, they will be allowed regardless of the counter/timer. - Any shift that is in progress when the counter reaches a maximum count in time will be allowed to complete before the default mode is entered. D-channel transitions during this period will not be counted towards the default mode limit. - A block, regardless of the direction, whether towards destination or back towards reversal target (shift timer expiring), will count as a value of 2 transitions towards the 30 segment transitions to go into default mode as defined above. Current attempt limit values are 30 transitions in 30 seconds and default mode values are 3 transitions every 15 seconds for 5 minutes. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Component ID: 410 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Description Circuit 1 SENSOR GROUND T160 20DG/WT Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 5 VOLT SUPPLY F856 20YL/PK 3 LINE PRESSURE SIGNAL T38 20YL/BR 4-- Component Location - 23 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 8111 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 8112 Fluid Pressure Sensor/Switch: Diagrams Component ID: 410 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Description Circuit 1 SENSOR GROUND T160 20DG/WT Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 5 VOLT SUPPLY F856 20YL/PK 3 LINE PRESSURE SIGNAL T38 20YL/BR 4-- Component Location - 23 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 8113 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description Fluid Pressure Sensor/Switch: Description and Operation Description DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, which is part of the pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the pump inlet. The system contains a Line Pressure Sensor, which is a direct input to the TCM. The line pressure sensor monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description > Page 8116 Fluid Pressure Sensor/Switch: Description and Operation Operation OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts, to ensure consistent shift quality. During all other operation, the desired line pressure value is adjusted based on torque level and other transmission requirements. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal Fluid Pressure Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal > Page 8119 Fluid Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Overdrive Switch: Locations Component ID: 490 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Description Circuit 123 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 4 GROUND Z71 20LB/BK 5 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 6 SENSOR GROUND T160 20DG/WT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 8123 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 8124 Overdrive Switch: Diagrams Component ID: 490 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Description Circuit 123 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 4 GROUND Z71 20LB/BK 5 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 6 SENSOR GROUND T160 20DG/WT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 8125 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 8126 Overdrive Switch: Testing and Inspection DIAGNOSIS AND TESTING - OVERDRIVE ELECTRICAL CONTROLS The tow/haul overdrive off switch, valve body solenoid, case connectors and related wiring can all be tested with a 12 volt test lamp or a volt/ohmmeter. Check continuity of each component when diagnosis indicates this is necessary. Switch and solenoid continuity should be checked whenever the transmission fails to shift into fourth gear range. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Switch: Service and Repair 42RLE Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8129 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8130 Overdrive Switch: Service and Repair 545RFE Automatic Transmission Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8131 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8132 Overdrive Switch: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8133 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8134 Overdrive Switch: Service and Repair AS68RC Automatic Transmission Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8135 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8140 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8141 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8142 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8143 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8144 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8145 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8146 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8147 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8148 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8149 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8150 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8153 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8154 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8155 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8156 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8157 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8158 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8159 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8160 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8161 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8162 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8163 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8166 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8167 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8168 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8169 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 8170 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 8173 TRS REMOVAL/INSTALLATION 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 8174 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 8175 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 8176 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 8177 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed Transmission Speed Sensor: Locations Sensor-Input Speed Component ID: 405 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8182 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8183 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8184 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8185 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8186 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8187 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8188 Transmission Speed Sensor: Locations Sensor-Output Speed Component ID: 415 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8189 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8190 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8191 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8192 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 18DG/BR 2 SPEED SENSOR GROUND T13 18DG/VT Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8193 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8194 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8195 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8196 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8197 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8198 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8199 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8200 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed Transmission Speed Sensor: Diagrams Sensor-Input Speed Component ID: 405 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8203 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8204 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8205 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8206 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8207 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8208 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8209 Transmission Speed Sensor: Diagrams Sensor-Output Speed Component ID: 415 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8210 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8211 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8212 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8213 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 18DG/BR 2 SPEED SENSOR GROUND T13 18DG/VT Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8214 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8215 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8216 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8217 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8218 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8219 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8220 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8221 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Speed Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The speed sensor (1) is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Operation OPERATION Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. Signals from this sensor are shared with the powertrain control module. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8224 Transmission Speed Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8225 Transmission Speed Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION INPUT AND OUTPUT SPEED SENSORS The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate DC square wave signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the "teeth" of the gear pass by the sensor coil, an DC square wave is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an DC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Transmission Speed Sensor: Service and Repair 68RFE Automatic Transmission Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the transmission case. Installation INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8228 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. Installation INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8229 Transmission Speed Sensor: Service and Repair AS68RC Automatic Transmission Output Speed Sensor OUTPUT SPEED SENSOR OUTPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor. 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. Input Speed Sensor INPUT SPEED SENSOR INPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8230 3. Remove the wiring connector from the input speed sensor. 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. Output Speed Sensor OUTPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. OUTPUT SPEED SENSOR 1. Lubricate the output speed sensor O-ring with MOPAR(R) AS68RC ATF. 2. Install the output speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the wiring connector onto the output speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC ATF as necessary. Input Speed Sensor INPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8231 INPUT SPEED SENSOR 1. Lubricate the output speed sensor O-ring with MOPAR(R) AS68RC ATF. 2. Install the input speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the electrical wiring connector onto the input speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC as necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Component ID: 431 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 TCC TEMPERATURE SIGNAL T819 20YL/VT 2 TEMPERATURE SENSOR GROUND T820 20YL/WT Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 8235 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 8236 Transmission Temperature Sensor/Switch: Diagrams Component ID: 431 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 TCC TEMPERATURE SIGNAL T819 20YL/VT 2 TEMPERATURE SENSOR GROUND T820 20YL/WT Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 8237 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection SWITCH-CLUTCH PEDAL POSITION 1. Disconnect switch 2-wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed - Continuity - Pedal Released - No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Description and Operation > Description Power Take-Off Switch: Description and Operation Description DESCRIPTION This Engine Control Module (ECM) input is used only on models equipped with aftermarket Power Take Off (PTO) units. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Description and Operation > Description > Page 8247 Power Take-Off Switch: Description and Operation Operation OPERATION This input is used only to tell the ECM that the aftermarket PTO (Power Take Off) unit has been engaged. The ECM will disable (temporarily shut down) certain OBD II diagnostic trouble codes when the PTO unit is engaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Component ID: 491 Component : SWITCH-TRANSFER CASE SELECTOR Connector: Name : SWITCH-TRANSFER CASE SELECTOR Color : BLACK # of pins : 10 Qualifier : (ETC) Pin Description Circuit 1 TRANSFER CASE POSITION SENSOR INPUT K77 20BR/WT 2-3 MODE SELECT K977 20BR/WT 4 PANEL LAMPS CONTROL E11 20OR/DB 5 GROUND Z905 20BK 6 NEUTRAL INDICATOR G95 20VT/BR 7 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 8-9-10 - Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 8252 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 8253 Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 8254 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 8255 Four Wheel Drive Selector Switch: Diagrams Component ID: 491 Component : SWITCH-TRANSFER CASE SELECTOR Connector: Name : SWITCH-TRANSFER CASE SELECTOR Color : BLACK # of pins : 10 Qualifier : (ETC) Pin Description Circuit 1 TRANSFER CASE POSITION SENSOR INPUT K77 20BR/WT 2-3 MODE SELECT K977 20BR/WT 4 PANEL LAMPS CONTROL E11 20OR/DB 5 GROUND Z905 20BK 6 NEUTRAL INDICATOR G95 20VT/BR 7 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 8-9-10 - Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 8256 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 8257 Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 8258 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case Four Wheel Drive Selector Switch: Description and Operation NV243 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 8261 For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere, is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 8262 Four Wheel Drive Selector Switch: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: - the AWD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 8263 The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 8264 Four Wheel Drive Selector Switch: Description and Operation NV246 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: - the AWD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 8265 For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 8266 Four Wheel Drive Selector Switch: Description and Operation NV273 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 8267 For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor Gear Sensor/Switch: Locations Assembly-Shift Motor/Mode Sensor Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 8272 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 8273 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 8274 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 8275 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 8276 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 8277 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 8278 Gear Sensor/Switch: Locations Sensor-Transfer Case Position Component ID: 429 Component : SENSOR-TRANSFER CASE POSITION Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC) Pin Description Circuit 1 MODE SENSOR A D201 20WT/DG Pin Description Circuit 1 MODE SENSOR A D201 18WT/DG 2 GROUND Z955 20BK 2 GROUND Z955 18BK 2 GROUND Z901 20BK Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 8279 Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 8280 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor Gear Sensor/Switch: Diagrams Assembly-Shift Motor/Mode Sensor Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 8283 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 8284 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 8285 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 8286 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 8287 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 8288 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 8289 Gear Sensor/Switch: Diagrams Sensor-Transfer Case Position Component ID: 429 Component : SENSOR-TRANSFER CASE POSITION Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC) Pin Description Circuit 1 MODE SENSOR A D201 20WT/DG Pin Description Circuit 1 MODE SENSOR A D201 18WT/DG 2 GROUND Z955 20BK 2 GROUND Z955 18BK 2 GROUND Z901 20BK Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 8290 Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 8291 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case Gear Sensor/Switch: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 8294 Mode Sensor Channel States Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 8295 Gear Sensor/Switch: Description and Operation NV246 Transfer Case Description DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The FCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Front Control Module (FCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to for the sensor codes returned to the FCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angle Vs. Transfer Case Position Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 8296 Mode Sensor Channel States Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 8297 Gear Sensor/Switch: Description and Operation NV271 Transfer Case Description DESCRIPTION The transfer case position sensor is an electronic device whose output can be interpreted to indicate the transfer case's current operating mode. The sensor consists of a five position, resistive multiplexed circuit which returns a specific resistance value to the Powertrain Control Module (PCM) for each transfer case operating mode. The sensor is located on the top of the transfer case, just left of the transfer case centerline and rides against the sector plate roostercomb. The PCM supplies 5VDC (+/- 0.5V) to the sensor and monitors the return voltage to determine the sector plate, and therefore the transfer case, position. Operation OPERATION Operating Mode Versus Resistance Position Sensor Linear Movement Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 8298 During normal vehicle operation, the Powertrain Control Module (PCM) monitors the transfer case position sensor return voltage to determine the operating mode of the transfer case. Refer to the Operating Mode Versus Resistance table for the correct resistance for each position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 8299 Gear Sensor/Switch: Description and Operation NV243 Transfer Case Description DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 8300 Mode Sensor Channel States Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 8301 Gear Sensor/Switch: Description and Operation NV273 Transfer Case Description DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 8302 Mode Sensor Channel States Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Removal Gear Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Disengage the transfer case position sensor connector from the position sensor. 3. Remove the position sensor from the transfer case. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Removal > Page 8305 Gear Sensor/Switch: Service and Repair Installation INSTALLATION 1. Inspect the O-ring seal on the transfer case position sensor. Replace the O-ring if necessary. 2. Install the transfer case position sensor into the transfer case. Torque the sensor to 27 Nm (20 ft.lbs.). 3. Engage the transfer case position sensor connector to the position sensor. 4. Lower vehicle. 5. Verify proper sensor operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front Speed Sensor: Locations Sensor-Prop Shaft Speed-Front Component ID: 420 Component : SENSOR-PROP SHAFT SPEED-FRONT Connector: Name : SENSOR-PROP SHAFT SPEED-FRONT Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR 2 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 8310 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 8311 Speed Sensor: Locations Sensor-Prop Shaft Speed-Rear Component ID: 421 Component : SENSOR-PROP SHAFT SPEED-REAR Connector: Name : SENSOR-PROP SHAFT SPEED-REAR Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 2 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 8312 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front Speed Sensor: Diagrams Sensor-Prop Shaft Speed-Front Component ID: 420 Component : SENSOR-PROP SHAFT SPEED-FRONT Connector: Name : SENSOR-PROP SHAFT SPEED-FRONT Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR 2 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 8315 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 8316 Speed Sensor: Diagrams Sensor-Prop Shaft Speed-Rear Component ID: 421 Component : SENSOR-PROP SHAFT SPEED-REAR Connector: Name : SENSOR-PROP SHAFT SPEED-REAR Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 2 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 8317 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Sensor-Output Shaft Speed-Front Speed Sensor: Service and Repair Sensor-Output Shaft Speed-Front Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connector from the front output shaft speed sensor (1). 3. Remove the front output shaft speed sensor from the transfer case. Installation INSTALLATION 1. Install the front output shaft speed sensor (1) into the transfer case. Tighten the speed sensor to 17 Nm (12.5 ft.lbs.). 2. Engage the wiring connector to the front output shaft speed sensor. 3. Lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Sensor-Output Shaft Speed-Front > Page 8320 Speed Sensor: Service and Repair Sensor-Output Shaft Speed-Rear Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connector from the rear output shaft speed sensor (1). 3. Remove the rear output shaft speed sensor from the transfer case. Installation INSTALLATION 1. Install the rear output shaft speed sensor (1) into the transfer case. Tighten the speed sensor to 17 Nm (12.5 ft.lbs.). 2. Engage the wiring connector to the rear output shaft speed sensor. 3. Lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness Technical Service Bulletin # K01 Date: 100510 Recall - ECM Update For OBD Readiness May 2010 Dealer Service Instructions for: California Emissions Recall K01 Reprogram ECM OBD Readiness Effective immediately all repairs on involved vehicles are to be performed according to this notification. Service Bulletin 18-038-09 is no longer applicable for the involved vehicles only. Models 2003 (DR) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETC) and a California emission control system (sales code NAE). 2006-2007 (DH/D1) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETH) and a California emission control system (sales code NAE). 2007 (DC) Dodge Ram Truck (3500 series cab chassis) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ) and a California emission control system (sales code NAE) built through January 5, 2007 (MDH010508). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process or GRS DealerCONNECT functions. Subject The Engine Control Module (ECM) on about 25,208 of the above vehicles may fail to accurately report diagnostic system information with some generic scan tools. This may cause the vehicle to be rejected or fail an Inspection/Maintenance Test (also known as a Smog Check). Repair The Engine Control Module (ECM) must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Part Number Description 04275086AB Authorized Modifications Label Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 8329 The special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the label plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 8330 To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: The DRBIII(R) must be used to perform this recall on 2003 Model Year (MY) vehicles. The 2003 MY procedure is found in Section D of the Service Procedure. Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall on 2006-2007 MY vehicles. This procedure must be performed with software release level 10.03 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 8331 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's" button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section E. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 8332 h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section E. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 8333 e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 10. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 9. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 10. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 11. Continue with Section E. Install Authorized Modification Label. D. Reprogram the ECM Using DRBIII(R): The DealerCONNECT System, DRBIII(R) (Diagnostic Readout Box scan tool), CH7000A flash cable and CH7035B data cable are required to perform this repair. Do not attempt to perform the flash procedure using an outdated CH7000/CH7001 flash cable. NOTE: Whenever a controller is reprogrammed, the software in the DRBIII scan tool must be programmed with the latest revision level available. NOTE: If the flash process is interrupted or aborted, the flash should be restarted and then follow the directions on the DRBIII scan tool. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 8334 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the DRBIII CH7000A flash cable from the DRBIII scan tool to the data link connector located inside the vehicle under the steering column. 3. Connect the CH7035B data cable from the DealerCONNECT machine to the MDS port on the DRBIII scan tool. 4. Place the vehicle's ignition key in the "RUN" position. 5. From the DealerCONNECT "WELCOME" screen, enter your "User I.D.," "Password" and "Dealer Code". 6. From the DealerCONNECT "HOME PAGE" select the "SERVICE" tab. 7. From the "SERVICE" tab screen select "TechTOOLS". 8. If the DRBIII scan tool does not "Auto Connect" select # 2 on the DRBIII key pad "Connect to TechCONNECT". 9. After the "Auto Connect" process is complete, select "READ PART NUMBER(S) FROM VEHICLE" on the TechCONNECT screen. 10. Continue following the TechCONNECT on-screen instructions. 11. Select the applicable update calibration. 12. Select the "DRBIII" button located at the bottom of the TechCONNECT monitor screen. 13. Select the "DOWNLOAD / UPDATE" button located next to the "DRBIII" button. NOTE: The system software will automatically download to the DRBIII scan tool. 14. After the software download to the DRBIII scan tool is complete, close the "DOWNLOAD / UPDATE PROGRESS" window. 15. Disconnect the DRBIII scan tool from the TechCONNECT CH7035B data cable. 16. Select # 1 "RETURN TO NORMAL MODE" on the DRBIII scan tool. 17. Use the following procedure to download the flash from the DRBIII scan tool to the vehicle. a. Select # 7 "VEHICLE FLASH" on the DRBIII scan tool. b. Follow the directions displayed on the DRBIII scan tool screen. c. After the reprogramming is complete, record the new module part number displayed on the DRBIII scan tool screen. d. Press the "PAGE BACK" button on the DRBIII scan tool. 18. Due to the ECM flash procedure, Diagnostic Trouble Codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS, ORC) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules, record the trouble codes, and erase the trouble codes using the following procedure: a. Turn the vehicle's ignition key to the "RUN" position. b. From the DRBIII scan tool Main Menu select # 1 "DRBIII Stand-Alone". c. From the DRBIII scan tool Stand-Alone menu select # 3 "Vehicle Module Scan". d. From the DRBIII scan tool Vehicle Module Scan menu select # 1 "1998 - 2005 Module Scan". e. Select "YES" on the DRBIII scan tool key pad to scan for DTC's. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 8335 f. Follow the instructions on the DRBIII scan tool screen. g. Once the scanning process is complete, the DRBIII scan tool will display a list of all the modules. Modules on the list that have an asterisk next to them have DTC's that need to be cleared. h. Select the module that needs to have the DTC's cleared and follow the instructions on the DRBIII scan tool screen to clear the DTC's. i. Turn the vehicle's ignition key to the "OFF" position. NOTE: Erase any DTC's in the ECM only after all other modules have had their DTC's erased. 19. Disconnect the DRBIII scan tool from the vehicle. 20. Turn off the battery charger and disconnect it from the vehicle. 21. Continue with Section E. Install Authorized Modification Label. E. Install the Authorized Modifications Label: 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 8336 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 8341 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 8342 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 8343 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 8344 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 8345 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 8346 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 8347 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 8352 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 8353 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 8354 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 8355 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 8356 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 8357 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 8358 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 07-003-10 > Sep > 10 > Engine Controls - ECM Update for Fan Clutch Operation PROM - Programmable Read Only Memory: Customer Interest Engine Controls - ECM Update for Fan Clutch Operation NUMBER: 07-003-10 GROUP: Cooling DATE: September 09, 2010 SUBJECT: High Coolant Temperatures On Vehicles Equipped With Snow Plows OVERVIEW: This bulletin provides information on how to program the Engine Control Module (ECM) to force the fan clutch to fully engage at all operating conditions MODELS: 2007 - 2010 DC/DM Ram 3500/4500/5500 Cab Chassis Trucks 2011 DD/DP Ram 3500/4500/5500 Cab Chassis Trucks NOTE: This bulletin applies to vehicles equipped with the 6.7L Cummins Diesel engine (Sales Code ETJ) DISCUSSION: Customers that operate their vehicle with a snowplow attached to the vehicle may cause the airflow passing through the radiator to be disrupted resulting in higher than normal engine temperatures The 6~7L Cummins ECM is equipped with software that can fully engage the fan clutch to allow an increase of airflow through the radiator Customers can initiate the fan clutch operation by performing the following button sequence NOTE: 2007 early 2009 models were not originally equipped with the fan clutch software however, recently released software does include this enhancement Ensure that the ECM software is at the latest level and if not, flash the ECM Refer to Service Bulletin 18-020-10 for additional information 1. Turn the ignition key to the run position or start the truck 2. Simultaneously press and release the Cruise Control "Cancel" button/lever and the "Exhaust Brake" button. Repeat this sequence four times within five seconds. The chime will sound twice as an audible indicator that the function is engaged 3. To disable the function, repeat the same procedure The chime will sound four times as an audible indicator that the function is disengaged NOTE: Customer's should be made aware that an increase in fan noise and a decrease in fuel economy may result when using this feature. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Engine Systems/Exhaust Enhancements NUMBER: 18-020-10 GROUP: Vehicle Performance DATE: June 10, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-06, DATED DECEMBER 05, 2006 AND 18-001-09, DATED JANUARY 21, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. Either wiTECH OR StarMOBILE DESKTOP CLIENT can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. StarMOBILE® SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. SUBJECT: FLASH: Engine Systems And Exhaust Aftertreatment Systems Enhancements OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement based on customer use and mileage accumulation. This bulletin involves: ^ Selectively erasing and reprogramming the Engine Control Module (PCM), 2007 - 2010 MY. ^ Selectively erasing and reprogramming the Cab Compartment Node (CCN), 2007 & 2008 MY. ^ If CCN is updated; provide a Customer Information Sheet explaining the overhead display messages. ^ One of several software changes allows for "Net Zero" and "Net Reduction" which will cause noticeable changes in idle speeds. Customers should be informed of these changes. They are explained in DISCUSSION, Improvements that address erroneous MIL illumination for DTC P0106, P0191, P2262 and P2299 DTC's, (spelled out in DISCUSSION below). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. MODELS: 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) 2008 - 2010 (DM) Ram Truck (4500/5500 Cab Chassis) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). NOTE: For some 2007 MY vehicles, the ECM flash is addressed in Recall K01, Dated May, 2010. Where applicable. please use the Recall to update the ECM and this bulletin to update the CCN software. DISCUSSION: Cab chassis trucks equipped with a 6.7L Cummins diesel have a number of software improvements available. This latest Service Bulletin (SB) will include improvements to prevent erroneous Malfunction Indicator Lamp (MIL) illumination: ^ P000F - Fuel System Over Pressure Relief Valve Activated Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 8368 ^ P0087 - Fuel Rail Pressure Too Low ^ P0106 - Manifold Absolute Pressure Sensor Performance ^ P0191 - Fuel Rail Pressure Sensor Circuit Performance ^ P1011 - Fuel Pump Delivery Pressure Too Low ^ P2299 - Brake Pedal Position / Accelerator Pedal Position Incompatible ^ P2262 - Turbocharger Boost Pressure Not Detected - Mechanical Other updates will include the following operational and diagnostic improvements: 1. Stationary DeSoot is now available with this software. This feature works similar to pick up truck (DH/D1) models. 2. New DTC added for P2563 - Turbocharger Boost Control Position Sensor Performance. This DTC indicates diminished variable geometry turbocharger travel, which is resolved by replacing the turbocharger. Diagnosis and repair procedures for the DTC have been published in DTC-Based Diagnostics in TechConnect. 3. The latest PCM software includes a new extended idle feature to accommodate the extended idle times present in some duty cycles. This feature may help to reduce the accumulation of soot in the exhaust aftertreatment system when the engine is idling for an extended period of time. Briefly how this feature works: a. As needed, the engine enters an idling mode which dramatically reduces the rate of soot accumulation in the diesel particulate filter (called "Net Zero"). Further, under extended idle periods of 5 minutes or longer, the engine enters a mode which reduces the amount of soot accumulated in the diesel particulate filter (called "Net Reduction"). While in these modes, the idle speed increases to 900 RPM for a period of time. The idle speed may return to normal idle speed and then return to 900 RPM to repeat this cycle during very long idle periods. b. These modes occur automatically depending on the need to regenerate the DPF as long as the vehicle is not driven over 20 MPH or operated at high load. If the vehicle is driven over 20 MPH normal mobile desoot will occur automatically. 4. New scan tool driven fuel system diagnostic tests (same as previously released in the pick up) now available for cab chassis. DIAGNOSIS: 1. Using the scan tool, determine current software level of the PCM and CCN. Record on the repair order, for later use, the current PCM and CCN software level part numbers. Proceed to the next step. 2. Compare the current PCM software level part number with software available in the scantool. Determine if the current PCM software level part number, recorded in Step # 1, is programmable to a higher level. 3. Is the part number of the current PCM level software (recorded in Step # 1) at the latest level listed in the scan tool? a. If YES >> then the PCM DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. b. If NO >> then the PCM DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. 4. Is the vehicle a 2007 OR 2008 MY? a. Yes >>> Proceed to Step # 5. b. No >>> 2009 MY proceed to the REPAIR PROCEDURE as required. 5. Determine if the current CCN module level software part number, that was recorded earlier in Step # 1, is one of the following (or with a higher suffix): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 8369 a. 05172187AH (or higher) = 2007 DC (3500). b. 05172334AG (or higher) = 2008 DC (3500) / DM (3500/4500). c. 2009 & 2010 MY vehicles came equipped with proper CCN software. 6. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 5? a. If YES >>> then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. b. If NO >>> then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. PARTS REQUIRED: REPAIR PROCEDURE; ECM MODULE REPROGRAM: NOTE: The wiTECH diagnostic application is the preferred method for flashing ECU's. Help using the wiTECH diagnostic application for flashing an ECU is available by selecting "Help" then "Help Contents" at the top of the wiTECH diagnostic application window. NOTE: The wiTECH software level must be at release 10.04 or higher to perform this procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. If required, as determined in DIAGNOSIS, above: reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > 8E - Electronic Control Modules >MODULE, Engine Control, Diesel > Service Information > Standard Procedure > PCM/ECM Programming - DIESEL. After PCM reprogramming, the following must be performed: a. Clear any DIG's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 3. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. 4. If required, as determined in DIAGNOSIS, above: reprogram the CCN using one of the following procedures, (based on scan tool use). 5. Was it determined in DIAGNOSIS, Step # 6 above, the CCN required updating? a. Yes >>> Proceed to appropriate CCN Module Reprogram Procedure Below, based on the scantool used. b. No >>> Repair is complete. NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 8370 NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. CCN MODULE REPROGRAM - USING wiTECH(R): 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id and "Password", then select "OK". 6. Select the "Next tab at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash" screen follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF position", remove the wiPOD(R) and battery charger from the vehicle. StarMOBILE(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident" flash file for statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 8371 b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step Se, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number (displayed at the end of the "Resident flash file for statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 8372 Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "Exhaust Filter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required - See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test PROM - Programmable Read Only Memory: Customer Interest Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 8377 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set PROM - Programmable Read Only Memory: Customer Interest Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 8382 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 8383 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 PROM - Programmable Read Only Memory: Customer Interest Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 8388 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 8389 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 8390 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 8391 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC P2262 Set NUMBER: 09-002-09 GROUP: Engine DATE: May 23, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-001-08 and 11-002-08 BOTH DATED MAY21, 2008. THIS ISA COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE STANDALONE MODE OR StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: MIL Illumination Due to DIG P2262 - Revised Diagnosis and Repair Procedures OVERVIEW: This bulletin discusses revised diagnostic and repair procedures for DTC P2262 Turbocharger Boost Pressure Not Detected - Mechanical. Recent PGM calibration updates have improved the robustness to this DIG through updated diagnostic strategies. As a result, many events which have no adverse affects on drivability, emissions, or reliability will no longer set the P2262 fault. MODELS: 2007 - 2009 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicle equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DTC): P2262 - Turbocharger Boost Pressure Not Detected - Mechanical. As a result of recent PCM calibration updates, the proper repair for some P2262 faults is to just update the calibration, while others will require cleaning or replacing the turbocharger. Scan Tool software update 9.05 (and later) includes a P2262 diagnosis test for this purpose. This diagnostic test uses Freeze Frame data stored in the PCM and a dynamic turbocharger response test to determine the correct repair for each truck with DTC P2262. The new P2262 diagnosis test must be used prior to performing any of the following: ^ Clearing codes. ^ Updating the PCM. ^ Beginning the turbocharger repair. The test must be used with the key in the run position with the engine off, and with coolant temperature between 50°F and 180° F. The time required to run this test will vary with the calibration level of the truck, from a few seconds up to a couple minutes. This is normal operation for the test. NOTE: The P2262 diagnosis test MUST NOT be used after the repair is complete, as this test CANNOT be used to confirm the repair. Test results will be inaccurate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set > Page 8396 If the customer is experiencing MIL illumination due to Diagnostic Trouble Code (DTC): P2262 Turbocharger Boost Pressure Not Detected - Mechanical follow the revised diagnosis and repair procedures below. NOTE: Using the wiTECH Diagnostic Application for flashing an ECU is made available through the wiTECH Diagnostic Application. For instructions select the "HELP" tab on upper portion of the wiTECH window, then "HELP CONTENTS." This will open the Welcome to wiTECH Help screen were help topics can now selected. SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: While the wiTECH tool is the preferred method of testing and flashing, StarMOBILE desktop client, StarMOBILE standalone mode OR StarSCAN may also be used to perform this procedure. NOTE: Please read through this entire Service Bulletin to gain a full understanding before performing the procedure. DIAGNOSIS: 1. Connect the Scan Tool to the Diagnostic Link Connector (DLC). 2. Turn the ignition key to the RUN position, DO NOT start the engine. 3. From the "Vehicle View" screen on the Scan Tool select: a. "All DTC's button. 4. Record all Diagnostic Trouble Codes (DTC's) that are present in the PCM. NOTE: DO NOT erase DTC's or reprogram the PCM at this point. If P2262 is not present in the PCM due to clearing the faults or reprogramming the PCM, the P2262 diagnosis test in Scan Tool will not run. NOTE: It is IMPORTANT to record (capture) all DTC's present in the PCM prior to proceeding further with this diagnosis. Procedures later may cause all DTC's to be erased. 5. Is DTC P2262 present in the PCM? a. If YES >> Proceed to Step # 6. b. If NO >> Then STOP. This bulletin does not apply. 6. Confirm the engine coolant temperature is between 50°F and 180°F. 7. Perform the P2262 diagnostic test with wiTECH(R), From the "Vehicle View screen select: a. Select "PCM". b. Select "Systems Tests". c. Select "P2262 Fault Diagnosis Test Start". d. Follow on-screen prompts to complete test. NOTE: If you receive an error message from test, confirm that the Diagnostic Link Connector and turbocharger actuator harness connections are secure. Also confirm that engine coolant temperature is between 50°F and 180°F, then run the test again. 8. Based on the outcome of the P2262 diagnosis test, the Scan Tool will provide one of the following as the proper direction for the appropriate repair. Based on these results, refer to the detailed service information available in DealerCONNECT > TechCONNECT under: Service Info and complete Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set > Page 8397 the repair as directed; a. Update PCM Flash Calibration to the latest calibration. No repair required to the turbocharger. b. Clean the Turbocharger. c. Update PCM Flash Calibration to the latest calibration and Clean the Turbocharger. d. Replace the Turbocharger. e. Update PCM Flash Calibration to the latest calibration and Replace the Turbocharger. 9. Does the vehicle have other DTC's as recorded in Step # 4 above? a. Yes >> Follow appropriate diagnosis procedures or TSB related to diagnosis and repair of each fault. b. No >> Repair complete. NOTE: All other DTC's or symptoms MUST be addressed prior to returning the vehicle to the customer. NOTE: When/if replacing Turbocharger, p/n 68048234AA or 68031095AA must NOT be used on a D1/DH (Pick Up) models. Turbocharger p/n 68048234AA or 68031095AA are to be used on DA/DC/DM (Cab/Chassis) ONLY. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift PROM - Programmable Read Only Memory: Customer Interest A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 8402 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 8403 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set PROM - Programmable Read Only Memory: Customer Interest A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8408 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8409 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8410 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8411 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-07 > May > 07 > Engine Controls - A/T May Default To Neutral PROM - Programmable Read Only Memory: Customer Interest Engine Controls - A/T May Default To Neutral NUMBER: 18-035-07 GROUP: Vehicle Performance DATE: May 18, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 545RFE Transmission Defaults To Neutral OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (ND) Dakota NOTE: This bulletin applies to vehicles equipped with a 545RFE transmission (sale code DGQ) built on or before March 26, 2007 (MDH 0326XX). SYMPTOM/CONDITION: The transmission may default into neutral gear if the transmission gear selector is moved into "reverse gear range under certain operating conditions. The default into neutral gear is done to protect the transmission mechanical components from potential damage. New PCM software will monitor transmission hydraulic pressure and allow reverse gear engagement, if the transmission is in "reverse gear range and the transmission hydraulic pressure is sufficient to support reverse gear operation. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-07 > May > 07 > Engine Controls - A/T May Default To Neutral > Page 8416 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN® must be programmed with software release level 7.04 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN® for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (PCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-07 > May > 07 > Engine Controls - A/T May Default To Neutral > Page 8417 i. Highlight the listed calibration. j. Select "Update Controller". k. When the PCM update is complete, select "OK". NOTE: Due to the ECU programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 07-003-10 > Sep > 10 > Engine Controls - ECM Update for Fan Clutch Operation PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - ECM Update for Fan Clutch Operation NUMBER: 07-003-10 GROUP: Cooling DATE: September 09, 2010 SUBJECT: High Coolant Temperatures On Vehicles Equipped With Snow Plows OVERVIEW: This bulletin provides information on how to program the Engine Control Module (ECM) to force the fan clutch to fully engage at all operating conditions MODELS: 2007 - 2010 DC/DM Ram 3500/4500/5500 Cab Chassis Trucks 2011 DD/DP Ram 3500/4500/5500 Cab Chassis Trucks NOTE: This bulletin applies to vehicles equipped with the 6.7L Cummins Diesel engine (Sales Code ETJ) DISCUSSION: Customers that operate their vehicle with a snowplow attached to the vehicle may cause the airflow passing through the radiator to be disrupted resulting in higher than normal engine temperatures The 6~7L Cummins ECM is equipped with software that can fully engage the fan clutch to allow an increase of airflow through the radiator Customers can initiate the fan clutch operation by performing the following button sequence NOTE: 2007 early 2009 models were not originally equipped with the fan clutch software however, recently released software does include this enhancement Ensure that the ECM software is at the latest level and if not, flash the ECM Refer to Service Bulletin 18-020-10 for additional information 1. Turn the ignition key to the run position or start the truck 2. Simultaneously press and release the Cruise Control "Cancel" button/lever and the "Exhaust Brake" button. Repeat this sequence four times within five seconds. The chime will sound twice as an audible indicator that the function is engaged 3. To disable the function, repeat the same procedure The chime will sound four times as an audible indicator that the function is disengaged NOTE: Customer's should be made aware that an increase in fan noise and a decrease in fuel economy may result when using this feature. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-001-10 > Jul > 10 > Diesel Engine - Dust/Debris Ingestion/Power Upgrade Info PROM - Programmable Read Only Memory: All Technical Service Bulletins Diesel Engine Dust/Debris Ingestion/Power Upgrade Info NUMBER: 09-001-10 GROUP: Engine DATE: July 2, 2010 SUBJECT: Dust-Out Diagnosis For Cummins Diesel Engines OVERVIEW: This bulletin involves proper inspection procedures to determine engine failure due to dust-out condition. Engines damaged due to the infiltration of dirt and/or debris through the air intake system are NOT WARRANTABLE. NOTE: Contact your Business Center or Service and Parts Area Manager if dust out evidence is noticed or any type of tampering is suspected. MODELS: 2003 - 2005 (DR) Ram Pick Up Truck (2500) 2006 - 2009 (DH) Ram Pick Up Truck (2500) 2010 - 2011 (DJ) Ram Pick Up Truck (2500) 2003 - 2005 (DR) Ram Pick Up Truck (3500) 2006 - 2009 (D1) Ram Pick Up Truck (3500) 2010 - 2011 (D2) Ram Pick Up Truck (3500) 2007 - 2010 (DC) Ram Truck Cab Chassis (3500) 2011 (DD) Ram Truck Cab Chassis (3500) 2008 - 2010 (DM) Ram Truck Cab Chassis (4500/5500) 2011 (DP) Ram Truck Cab Chassis (4500/5500) NOTE: This bulletin applies to any Cummins diesel equipped vehicle still covered under the manufacturers warranty. SYMPTOM/CONDITION: Engines that exhibit particular symptoms that may have been caused by improper air filtration. Some of these symptoms are listed below (not limited to) ^ Knocking ^ Hard or no start ^ Low power / poor performance ^ Oil consumption ^ Lower end bearing failure ^ Smoking ^ Blow-by (rings not sealing) ^ Oil on turbo (dust damage to seal/bearing) NOTE: See the "Cummins Diesel Dust-Out Inspection for Warranty" document located in eFiles Under: Service> STAR Center> Cummins - HEV Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-001-10 > Jul > 10 > Diesel Engine - Dust/Debris Ingestion/Power Upgrade Info > Page 8427 documents for pictures regarding dust-outs. NOTE: Canadian dealers can refer to Tech-Tip # 18 - CUMMINS DIESEL ENGINES FAILURES DO TO DIRTY AIR ENTERING THE INDUCTION SYSTEM - HOW TO INSPECT FOR SIGNS OF A "DUST OUT" ENGINE FAILURE sent 05/19/2010 for pictures regarding dust-outs. DIAGNOSIS: 1. Perform a compression test. Low compression is generally due to ring/piston/valve issues. High compression may be due to oil infiltration causing a hydraulic effect. 2. Major mechanical damage can also be caused by fuel, fuel injectors or "Up-rate kits or "programmers". Inspect vehicle for any device that adds more power, (fuel) which may damage the engine mechanically. Check for any aftermarket power enhancer or "box" or "downloader".Repairs of failures caused by these devices do not qualify for warranty coverage. 3. Inspect all air handling ducts and components. (See eFiles document). If dirt is found in the air handling components, further diagnostics may not be necessary. Engines with dirt detected on the "clean side" of air filter will not qualify for warranty coverage. 4. Inspect for aftermarket "cold air" performance air filter housing, duct work and filters. Again, Engines with dirt detected on the "clean side" of air filter will not qualify for warranty coverage. 5. Inspect cylinder bore(s) for cross-hatching and excessive piston ring ridge. The absence of cylinder bore cross-hatching MAY be one of the first signs of cylinder dust or dirt damage. Cylinder bore(s) for cross-hatching and excessive piston ring ridge may be inspected using a bore scope (if available), or cylinder head removal may be necessary. Contact your Business Center or Service and Parts Area Manager if dust out evidence is noticed or any type of tampering is suspected. Dirt carried in through the air handling system is typically funneled and concentrated to the end (1 & 6) cylinders*. Vertical scratches (broken rings) will follow. Generally, a properly maintained engine will have well defined hone marks visible beyond 100,000 miles. NOTE: Be aware of stains or marks in cylinder wall(s). Marks may follow the ring gap but have no depth or damage to the cylinder bore wall. These marks have a look similar to a "scored" cylinder, yet have no physical damage to the surface and will not cause any harm. These marks be checked by physically inspecting (scratching) the surface to detect if cylinder wall is damaged (grooved). 6. When inspecting the cylinder bore(s), compare cylinders # 1 & # 6 to the others. Cylinder honing (cross-hatching) performed in the Cummins engine manufacturing process is very aggressive. Engines that have dirt introduced will "polish out" this hone witness mark first and then start cutting or wearing down the cylinder walls which will create a ring ridge in the cylinder bore at the top of the bore. The absence of the cross-hatching ALONG WITH dirt found anywhere in the "clean-side" of the air intake system, is evidence of a dust-out condition. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Engine Systems/Exhaust Enhancements NUMBER: 18-020-10 GROUP: Vehicle Performance DATE: June 10, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-06, DATED DECEMBER 05, 2006 AND 18-001-09, DATED JANUARY 21, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. Either wiTECH OR StarMOBILE DESKTOP CLIENT can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. StarMOBILE® SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. SUBJECT: FLASH: Engine Systems And Exhaust Aftertreatment Systems Enhancements OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement based on customer use and mileage accumulation. This bulletin involves: ^ Selectively erasing and reprogramming the Engine Control Module (PCM), 2007 - 2010 MY. ^ Selectively erasing and reprogramming the Cab Compartment Node (CCN), 2007 & 2008 MY. ^ If CCN is updated; provide a Customer Information Sheet explaining the overhead display messages. ^ One of several software changes allows for "Net Zero" and "Net Reduction" which will cause noticeable changes in idle speeds. Customers should be informed of these changes. They are explained in DISCUSSION, Improvements that address erroneous MIL illumination for DTC P0106, P0191, P2262 and P2299 DTC's, (spelled out in DISCUSSION below). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. MODELS: 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) 2008 - 2010 (DM) Ram Truck (4500/5500 Cab Chassis) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). NOTE: For some 2007 MY vehicles, the ECM flash is addressed in Recall K01, Dated May, 2010. Where applicable. please use the Recall to update the ECM and this bulletin to update the CCN software. DISCUSSION: Cab chassis trucks equipped with a 6.7L Cummins diesel have a number of software improvements available. This latest Service Bulletin (SB) will include improvements to prevent erroneous Malfunction Indicator Lamp (MIL) illumination: ^ P000F - Fuel System Over Pressure Relief Valve Activated Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 8432 ^ P0087 - Fuel Rail Pressure Too Low ^ P0106 - Manifold Absolute Pressure Sensor Performance ^ P0191 - Fuel Rail Pressure Sensor Circuit Performance ^ P1011 - Fuel Pump Delivery Pressure Too Low ^ P2299 - Brake Pedal Position / Accelerator Pedal Position Incompatible ^ P2262 - Turbocharger Boost Pressure Not Detected - Mechanical Other updates will include the following operational and diagnostic improvements: 1. Stationary DeSoot is now available with this software. This feature works similar to pick up truck (DH/D1) models. 2. New DTC added for P2563 - Turbocharger Boost Control Position Sensor Performance. This DTC indicates diminished variable geometry turbocharger travel, which is resolved by replacing the turbocharger. Diagnosis and repair procedures for the DTC have been published in DTC-Based Diagnostics in TechConnect. 3. The latest PCM software includes a new extended idle feature to accommodate the extended idle times present in some duty cycles. This feature may help to reduce the accumulation of soot in the exhaust aftertreatment system when the engine is idling for an extended period of time. Briefly how this feature works: a. As needed, the engine enters an idling mode which dramatically reduces the rate of soot accumulation in the diesel particulate filter (called "Net Zero"). Further, under extended idle periods of 5 minutes or longer, the engine enters a mode which reduces the amount of soot accumulated in the diesel particulate filter (called "Net Reduction"). While in these modes, the idle speed increases to 900 RPM for a period of time. The idle speed may return to normal idle speed and then return to 900 RPM to repeat this cycle during very long idle periods. b. These modes occur automatically depending on the need to regenerate the DPF as long as the vehicle is not driven over 20 MPH or operated at high load. If the vehicle is driven over 20 MPH normal mobile desoot will occur automatically. 4. New scan tool driven fuel system diagnostic tests (same as previously released in the pick up) now available for cab chassis. DIAGNOSIS: 1. Using the scan tool, determine current software level of the PCM and CCN. Record on the repair order, for later use, the current PCM and CCN software level part numbers. Proceed to the next step. 2. Compare the current PCM software level part number with software available in the scantool. Determine if the current PCM software level part number, recorded in Step # 1, is programmable to a higher level. 3. Is the part number of the current PCM level software (recorded in Step # 1) at the latest level listed in the scan tool? a. If YES >> then the PCM DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. b. If NO >> then the PCM DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. 4. Is the vehicle a 2007 OR 2008 MY? a. Yes >>> Proceed to Step # 5. b. No >>> 2009 MY proceed to the REPAIR PROCEDURE as required. 5. Determine if the current CCN module level software part number, that was recorded earlier in Step # 1, is one of the following (or with a higher suffix): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 8433 a. 05172187AH (or higher) = 2007 DC (3500). b. 05172334AG (or higher) = 2008 DC (3500) / DM (3500/4500). c. 2009 & 2010 MY vehicles came equipped with proper CCN software. 6. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 5? a. If YES >>> then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. b. If NO >>> then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. PARTS REQUIRED: REPAIR PROCEDURE; ECM MODULE REPROGRAM: NOTE: The wiTECH diagnostic application is the preferred method for flashing ECU's. Help using the wiTECH diagnostic application for flashing an ECU is available by selecting "Help" then "Help Contents" at the top of the wiTECH diagnostic application window. NOTE: The wiTECH software level must be at release 10.04 or higher to perform this procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. If required, as determined in DIAGNOSIS, above: reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > 8E - Electronic Control Modules >MODULE, Engine Control, Diesel > Service Information > Standard Procedure > PCM/ECM Programming - DIESEL. After PCM reprogramming, the following must be performed: a. Clear any DIG's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 3. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. 4. If required, as determined in DIAGNOSIS, above: reprogram the CCN using one of the following procedures, (based on scan tool use). 5. Was it determined in DIAGNOSIS, Step # 6 above, the CCN required updating? a. Yes >>> Proceed to appropriate CCN Module Reprogram Procedure Below, based on the scantool used. b. No >>> Repair is complete. NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 8434 NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. CCN MODULE REPROGRAM - USING wiTECH(R): 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id and "Password", then select "OK". 6. Select the "Next tab at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash" screen follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF position", remove the wiPOD(R) and battery charger from the vehicle. StarMOBILE(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident" flash file for statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 8435 b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step Se, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number (displayed at the end of the "Resident flash file for statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 8436 Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "Exhaust Filter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required - See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test PROM - Programmable Read Only Memory: All Technical Service Bulletins Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 8441 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine, A/T Controls MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 8446 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 8447 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > K01 > May > 10 > Recall - ECM Update For OBD Readiness Technical Service Bulletin # K01 Date: 100510 Recall - ECM Update For OBD Readiness May 2010 Dealer Service Instructions for: California Emissions Recall K01 Reprogram ECM OBD Readiness Effective immediately all repairs on involved vehicles are to be performed according to this notification. Service Bulletin 18-038-09 is no longer applicable for the involved vehicles only. Models 2003 (DR) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETC) and a California emission control system (sales code NAE). 2006-2007 (DH/D1) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETH) and a California emission control system (sales code NAE). 2007 (DC) Dodge Ram Truck (3500 series cab chassis) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ) and a California emission control system (sales code NAE) built through January 5, 2007 (MDH010508). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process or GRS DealerCONNECT functions. Subject The Engine Control Module (ECM) on about 25,208 of the above vehicles may fail to accurately report diagnostic system information with some generic scan tools. This may cause the vehicle to be rejected or fail an Inspection/Maintenance Test (also known as a Smog Check). Repair The Engine Control Module (ECM) must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Part Number Description 04275086AB Authorized Modifications Label Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 8452 The special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the label plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 8453 To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: The DRBIII(R) must be used to perform this recall on 2003 Model Year (MY) vehicles. The 2003 MY procedure is found in Section D of the Service Procedure. Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall on 2006-2007 MY vehicles. This procedure must be performed with software release level 10.03 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 8454 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's" button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section E. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 8455 h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section E. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 8456 e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 10. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 9. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 10. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 11. Continue with Section E. Install Authorized Modification Label. D. Reprogram the ECM Using DRBIII(R): The DealerCONNECT System, DRBIII(R) (Diagnostic Readout Box scan tool), CH7000A flash cable and CH7035B data cable are required to perform this repair. Do not attempt to perform the flash procedure using an outdated CH7000/CH7001 flash cable. NOTE: Whenever a controller is reprogrammed, the software in the DRBIII scan tool must be programmed with the latest revision level available. NOTE: If the flash process is interrupted or aborted, the flash should be restarted and then follow the directions on the DRBIII scan tool. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 8457 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the DRBIII CH7000A flash cable from the DRBIII scan tool to the data link connector located inside the vehicle under the steering column. 3. Connect the CH7035B data cable from the DealerCONNECT machine to the MDS port on the DRBIII scan tool. 4. Place the vehicle's ignition key in the "RUN" position. 5. From the DealerCONNECT "WELCOME" screen, enter your "User I.D.," "Password" and "Dealer Code". 6. From the DealerCONNECT "HOME PAGE" select the "SERVICE" tab. 7. From the "SERVICE" tab screen select "TechTOOLS". 8. If the DRBIII scan tool does not "Auto Connect" select # 2 on the DRBIII key pad "Connect to TechCONNECT". 9. After the "Auto Connect" process is complete, select "READ PART NUMBER(S) FROM VEHICLE" on the TechCONNECT screen. 10. Continue following the TechCONNECT on-screen instructions. 11. Select the applicable update calibration. 12. Select the "DRBIII" button located at the bottom of the TechCONNECT monitor screen. 13. Select the "DOWNLOAD / UPDATE" button located next to the "DRBIII" button. NOTE: The system software will automatically download to the DRBIII scan tool. 14. After the software download to the DRBIII scan tool is complete, close the "DOWNLOAD / UPDATE PROGRESS" window. 15. Disconnect the DRBIII scan tool from the TechCONNECT CH7035B data cable. 16. Select # 1 "RETURN TO NORMAL MODE" on the DRBIII scan tool. 17. Use the following procedure to download the flash from the DRBIII scan tool to the vehicle. a. Select # 7 "VEHICLE FLASH" on the DRBIII scan tool. b. Follow the directions displayed on the DRBIII scan tool screen. c. After the reprogramming is complete, record the new module part number displayed on the DRBIII scan tool screen. d. Press the "PAGE BACK" button on the DRBIII scan tool. 18. Due to the ECM flash procedure, Diagnostic Trouble Codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS, ORC) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules, record the trouble codes, and erase the trouble codes using the following procedure: a. Turn the vehicle's ignition key to the "RUN" position. b. From the DRBIII scan tool Main Menu select # 1 "DRBIII Stand-Alone". c. From the DRBIII scan tool Stand-Alone menu select # 3 "Vehicle Module Scan". d. From the DRBIII scan tool Vehicle Module Scan menu select # 1 "1998 - 2005 Module Scan". e. Select "YES" on the DRBIII scan tool key pad to scan for DTC's. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 8458 f. Follow the instructions on the DRBIII scan tool screen. g. Once the scanning process is complete, the DRBIII scan tool will display a list of all the modules. Modules on the list that have an asterisk next to them have DTC's that need to be cleared. h. Select the module that needs to have the DTC's cleared and follow the instructions on the DRBIII scan tool screen to clear the DTC's. i. Turn the vehicle's ignition key to the "OFF" position. NOTE: Erase any DTC's in the ECM only after all other modules have had their DTC's erased. 19. Disconnect the DRBIII scan tool from the vehicle. 20. Turn off the battery charger and disconnect it from the vehicle. 21. Continue with Section E. Install Authorized Modification Label. E. Install the Authorized Modifications Label: 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 8459 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 PROM - Programmable Read Only Memory: All Technical Service Bulletins Computers/Controls CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 8464 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 8465 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 8466 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 8467 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 8472 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 8473 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 8474 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 8475 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 8476 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 8477 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 8478 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC P2262 Set NUMBER: 09-002-09 GROUP: Engine DATE: May 23, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-001-08 and 11-002-08 BOTH DATED MAY21, 2008. THIS ISA COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE STANDALONE MODE OR StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: MIL Illumination Due to DIG P2262 - Revised Diagnosis and Repair Procedures OVERVIEW: This bulletin discusses revised diagnostic and repair procedures for DTC P2262 Turbocharger Boost Pressure Not Detected - Mechanical. Recent PGM calibration updates have improved the robustness to this DIG through updated diagnostic strategies. As a result, many events which have no adverse affects on drivability, emissions, or reliability will no longer set the P2262 fault. MODELS: 2007 - 2009 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicle equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DTC): P2262 - Turbocharger Boost Pressure Not Detected - Mechanical. As a result of recent PCM calibration updates, the proper repair for some P2262 faults is to just update the calibration, while others will require cleaning or replacing the turbocharger. Scan Tool software update 9.05 (and later) includes a P2262 diagnosis test for this purpose. This diagnostic test uses Freeze Frame data stored in the PCM and a dynamic turbocharger response test to determine the correct repair for each truck with DTC P2262. The new P2262 diagnosis test must be used prior to performing any of the following: ^ Clearing codes. ^ Updating the PCM. ^ Beginning the turbocharger repair. The test must be used with the key in the run position with the engine off, and with coolant temperature between 50°F and 180° F. The time required to run this test will vary with the calibration level of the truck, from a few seconds up to a couple minutes. This is normal operation for the test. NOTE: The P2262 diagnosis test MUST NOT be used after the repair is complete, as this test CANNOT be used to confirm the repair. Test results will be inaccurate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set > Page 8483 If the customer is experiencing MIL illumination due to Diagnostic Trouble Code (DTC): P2262 Turbocharger Boost Pressure Not Detected - Mechanical follow the revised diagnosis and repair procedures below. NOTE: Using the wiTECH Diagnostic Application for flashing an ECU is made available through the wiTECH Diagnostic Application. For instructions select the "HELP" tab on upper portion of the wiTECH window, then "HELP CONTENTS." This will open the Welcome to wiTECH Help screen were help topics can now selected. SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: While the wiTECH tool is the preferred method of testing and flashing, StarMOBILE desktop client, StarMOBILE standalone mode OR StarSCAN may also be used to perform this procedure. NOTE: Please read through this entire Service Bulletin to gain a full understanding before performing the procedure. DIAGNOSIS: 1. Connect the Scan Tool to the Diagnostic Link Connector (DLC). 2. Turn the ignition key to the RUN position, DO NOT start the engine. 3. From the "Vehicle View" screen on the Scan Tool select: a. "All DTC's button. 4. Record all Diagnostic Trouble Codes (DTC's) that are present in the PCM. NOTE: DO NOT erase DTC's or reprogram the PCM at this point. If P2262 is not present in the PCM due to clearing the faults or reprogramming the PCM, the P2262 diagnosis test in Scan Tool will not run. NOTE: It is IMPORTANT to record (capture) all DTC's present in the PCM prior to proceeding further with this diagnosis. Procedures later may cause all DTC's to be erased. 5. Is DTC P2262 present in the PCM? a. If YES >> Proceed to Step # 6. b. If NO >> Then STOP. This bulletin does not apply. 6. Confirm the engine coolant temperature is between 50°F and 180°F. 7. Perform the P2262 diagnostic test with wiTECH(R), From the "Vehicle View screen select: a. Select "PCM". b. Select "Systems Tests". c. Select "P2262 Fault Diagnosis Test Start". d. Follow on-screen prompts to complete test. NOTE: If you receive an error message from test, confirm that the Diagnostic Link Connector and turbocharger actuator harness connections are secure. Also confirm that engine coolant temperature is between 50°F and 180°F, then run the test again. 8. Based on the outcome of the P2262 diagnosis test, the Scan Tool will provide one of the following as the proper direction for the appropriate repair. Based on these results, refer to the detailed service information available in DealerCONNECT > TechCONNECT under: Service Info and complete Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set > Page 8484 the repair as directed; a. Update PCM Flash Calibration to the latest calibration. No repair required to the turbocharger. b. Clean the Turbocharger. c. Update PCM Flash Calibration to the latest calibration and Clean the Turbocharger. d. Replace the Turbocharger. e. Update PCM Flash Calibration to the latest calibration and Replace the Turbocharger. 9. Does the vehicle have other DTC's as recorded in Step # 4 above? a. Yes >> Follow appropriate diagnosis procedures or TSB related to diagnosis and repair of each fault. b. No >> Repair complete. NOTE: All other DTC's or symptoms MUST be addressed prior to returning the vehicle to the customer. NOTE: When/if replacing Turbocharger, p/n 68048234AA or 68031095AA must NOT be used on a D1/DH (Pick Up) models. Turbocharger p/n 68048234AA or 68031095AA are to be used on DA/DC/DM (Cab/Chassis) ONLY. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 8489 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 8490 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 8495 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 8496 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 8497 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 8498 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 8499 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 8500 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 8501 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8506 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8507 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8508 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8509 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-035-07 > May > 07 > Engine Controls - A/T May Default To Neutral PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - A/T May Default To Neutral NUMBER: 18-035-07 GROUP: Vehicle Performance DATE: May 18, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 545RFE Transmission Defaults To Neutral OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (ND) Dakota NOTE: This bulletin applies to vehicles equipped with a 545RFE transmission (sale code DGQ) built on or before March 26, 2007 (MDH 0326XX). SYMPTOM/CONDITION: The transmission may default into neutral gear if the transmission gear selector is moved into "reverse gear range under certain operating conditions. The default into neutral gear is done to protect the transmission mechanical components from potential damage. New PCM software will monitor transmission hydraulic pressure and allow reverse gear engagement, if the transmission is in "reverse gear range and the transmission hydraulic pressure is sufficient to support reverse gear operation. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-035-07 > May > 07 > Engine Controls - A/T May Default To Neutral > Page 8514 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN® must be programmed with software release level 7.04 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN® for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (PCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-035-07 > May > 07 > Engine Controls - A/T May Default To Neutral > Page 8515 i. Highlight the listed calibration. j. Select "Update Controller". k. When the PCM update is complete, select "OK". NOTE: Due to the ECU programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Flash Reprogramming Abort Recovery NUMBER: 18-001-06 REV. A GROUP: Vehicle Performance DATE: July 12, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-001-06, DATED JANUARY II, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, YEARS AND A REVISED DISCUSSION ABOUT ABORTED FLASH REPROGRAMMING RECOVERY. SUBJECT: StarSCAN(R)/StarMOBILE(TM) Abort Recovery Procedures OVERVIEW: This Bulletin provides guidelines to minimize flash reprogramming problems and recovery procedure information for failed flash attempts. MODELS: **2007 (DC) Ram Cab & Chassis** 2006 - **2007** (DR/DH/D1) Ram Truck 2004 - **2007** (HB/HG) Durango/Aspen 2007 (JK) Wrangler **2007 (JS) Sebring** **2007 (KA) Nitro** 2006 - **2007** (KJ) Liberty/Cherokee 2005 - **2007** (LX/LE) 300/Magnum/Charger **2007 (MK) Compass** 2005 - **2007** (ND) Dakota **2007 (PM) Caliber** 2006 - **2007* (PT) PT Cruiser 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK/XH) Commander DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable. Replacing a module that is recoverable is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent unnecessary replacement of control modules. GENERAL: Flash Reprogramming is only authorized when programming a generic module or by a specific SERVICE ACTION (Service Bulletin/Recall/Rapid Response Transmittal/Advance Service Information). CAUTION: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery > Page 8520 When updating a module because of a Service Action, it is important to follow the steps outlined in the Repair Procedure section of the Service Action. Procedures may differ depending on the module that is being reprogrammed. Review the entire Service Action prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Action. COMMON CAUSES OF FLASH REPROGRAMMING ERRORS Interruptions, voltage problems, a variety of other outside interactions, and failure to follow the steps outlined in the Service Action can potentially interfere with the process. This document seeks to provide information to minimize problems associated with module flash reprogramming. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session, make sure you have the most current software installed in the scan tool (StarSCAN(R)/StarMOBILE(TM)). Refer to the current software release information available in TechCONNECT, under: Service Info > StarSCAN(R) and StarMOBILE(TM) Tools > Latest News > Select the most recent release number. The technician will be able to see the applicable version numbers. Often, because of multiple StarSCAN(R)/StarMOBILE(TM)s in the shop, not all devices will get updated in a timely manner. The installed StarSCAN(R)/StarMOBILE(TM) software version and scan tool operating system version, (Fig. 2), can be verified from the "Home" screen as follows: StarMOBILE Desktop Client ^ Select "Tool Menu". ^ Select "Version Information" Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery > Page 8521 StarSCAN ^ Select "Show Shortcuts" ^ Select "Tool Menu". ^ Select "Version Information" Typical Tool Menu (Fig. 1) NOTE: The StarSCAN also displays the version number on the right side of the blue header at the top of each screen. NOTE: To read the version on the StarMOBILE(TM), it must be connected and the application running or the user will receive "N/A" for the "System" value. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. It is a good practice to have dedicated cables devoted to "Flash ONLY". Always have a spare StarSCAN(R) CH9404 (vehicle) cable available. Always have a spare StarMOBILE(TM) CH9804 (vehicle) cable available (blue cable end). Diagnosing vehicle cable problems Inspect vehicle cable connectors for potential problems that might cause communication interruptions. Use the information available on DealerCONNECT under: ^ eSupport (above the "Marketing" tab) ^ Under "Knowledge Center" - select "Find Answers" ^ In the "Enter link, error message, or topic" area, type "561" ^ In the "Search By" area, select "Answer ID" ^ At the next screen, select the "StarSCAN Flash Lockup.pdf" link to access the information to diagnose suspect vehicle cable continuity. FLASH REPROGRAMMING PROBLEM PREVENTION ^ Follow the steps outlined in the Service Action. ^ Pay attention to the screen prompts displayed during the flash process. ^ Replace worn cables. ^ Verify the vehicle is equipped with a known good battery. ^ Ensure the battery charger charging rate provides approximately 13.2 - 13.8 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. **ABORTED FLASH REPROGRAMMING RECOVERY** ** The following steps may help recover a non-responsive module when the flash process is aborted or interrupted. 1. When the Flash ECU screen displays an Error Message, select OK. 2. Turn the ignition to "off" and power down the StarSCAN(R). 3. Turn the vehicle ignition to the "On" position. 4. Power on the StarSCAN®. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery > Page 8522 NOTE: If the technician was flashing a PCM, the tool may display "Unknown VIN". Disregard this. 5. Select (ECU) View. 6. Highlight the ECU that was being flashed. NOTE: The module may appear to be non-responsive. Highlight the module anyway. 7. Select More Options 8. Select ECU Flash 9. If the "Flash ECU" screen displays "Resident flash files for Part # XXXXX", the module should be recoverable. If the screen displays "No resident flash files found" the module is not recoverable. Does the Flash ECU screen display "No resident flash files found?" a. Yes >> The module must be replaced. b. No >> proceed to Step # 10. 10. Is a calibration file displayed on the StarSCAN(R)? a. Yes >> proceed to Step # 11. b. No >> Select "Browse For New File" and follow on screen instructions. Highlight the calibration that was previously chosen. Select "Download to Scantool". When the file is downloaded to the scantool, select "Back" and proceed to Step # 11. 11. Highlight the appropriate calibration. 12. Select "Update Controller" and follow the on screen instructions. 13. When the flash is complete, verify the "Resident flash file part number" matches the 'New PIN" of the appropriate calibration. 14. Proceed with the steps listed in the Service Bulletin to complete the service action.** NOTE: If after following the steps above, you are still having issues performing the flash reprogramming procedure using a specific StarSCAN(R)/StarMOBILE(R) it is suggested to contact SPX/Miller Special Tools for service. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 07-003-10 > Sep > 10 > Engine Controls - ECM Update for Fan Clutch Operation PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - ECM Update for Fan Clutch Operation NUMBER: 07-003-10 GROUP: Cooling DATE: September 09, 2010 SUBJECT: High Coolant Temperatures On Vehicles Equipped With Snow Plows OVERVIEW: This bulletin provides information on how to program the Engine Control Module (ECM) to force the fan clutch to fully engage at all operating conditions MODELS: 2007 - 2010 DC/DM Ram 3500/4500/5500 Cab Chassis Trucks 2011 DD/DP Ram 3500/4500/5500 Cab Chassis Trucks NOTE: This bulletin applies to vehicles equipped with the 6.7L Cummins Diesel engine (Sales Code ETJ) DISCUSSION: Customers that operate their vehicle with a snowplow attached to the vehicle may cause the airflow passing through the radiator to be disrupted resulting in higher than normal engine temperatures The 6~7L Cummins ECM is equipped with software that can fully engage the fan clutch to allow an increase of airflow through the radiator Customers can initiate the fan clutch operation by performing the following button sequence NOTE: 2007 early 2009 models were not originally equipped with the fan clutch software however, recently released software does include this enhancement Ensure that the ECM software is at the latest level and if not, flash the ECM Refer to Service Bulletin 18-020-10 for additional information 1. Turn the ignition key to the run position or start the truck 2. Simultaneously press and release the Cruise Control "Cancel" button/lever and the "Exhaust Brake" button. Repeat this sequence four times within five seconds. The chime will sound twice as an audible indicator that the function is engaged 3. To disable the function, repeat the same procedure The chime will sound four times as an audible indicator that the function is disengaged NOTE: Customer's should be made aware that an increase in fan noise and a decrease in fuel economy may result when using this feature. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-001-10 > Jul > 10 > Diesel Engine - Dust/Debris Ingestion/Power Upgrade Info PROM - Programmable Read Only Memory: All Technical Service Bulletins Diesel Engine Dust/Debris Ingestion/Power Upgrade Info NUMBER: 09-001-10 GROUP: Engine DATE: July 2, 2010 SUBJECT: Dust-Out Diagnosis For Cummins Diesel Engines OVERVIEW: This bulletin involves proper inspection procedures to determine engine failure due to dust-out condition. Engines damaged due to the infiltration of dirt and/or debris through the air intake system are NOT WARRANTABLE. NOTE: Contact your Business Center or Service and Parts Area Manager if dust out evidence is noticed or any type of tampering is suspected. MODELS: 2003 - 2005 (DR) Ram Pick Up Truck (2500) 2006 - 2009 (DH) Ram Pick Up Truck (2500) 2010 - 2011 (DJ) Ram Pick Up Truck (2500) 2003 - 2005 (DR) Ram Pick Up Truck (3500) 2006 - 2009 (D1) Ram Pick Up Truck (3500) 2010 - 2011 (D2) Ram Pick Up Truck (3500) 2007 - 2010 (DC) Ram Truck Cab Chassis (3500) 2011 (DD) Ram Truck Cab Chassis (3500) 2008 - 2010 (DM) Ram Truck Cab Chassis (4500/5500) 2011 (DP) Ram Truck Cab Chassis (4500/5500) NOTE: This bulletin applies to any Cummins diesel equipped vehicle still covered under the manufacturers warranty. SYMPTOM/CONDITION: Engines that exhibit particular symptoms that may have been caused by improper air filtration. Some of these symptoms are listed below (not limited to) ^ Knocking ^ Hard or no start ^ Low power / poor performance ^ Oil consumption ^ Lower end bearing failure ^ Smoking ^ Blow-by (rings not sealing) ^ Oil on turbo (dust damage to seal/bearing) NOTE: See the "Cummins Diesel Dust-Out Inspection for Warranty" document located in eFiles Under: Service> STAR Center> Cummins - HEV Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-001-10 > Jul > 10 > Diesel Engine - Dust/Debris Ingestion/Power Upgrade Info > Page 8532 documents for pictures regarding dust-outs. NOTE: Canadian dealers can refer to Tech-Tip # 18 - CUMMINS DIESEL ENGINES FAILURES DO TO DIRTY AIR ENTERING THE INDUCTION SYSTEM - HOW TO INSPECT FOR SIGNS OF A "DUST OUT" ENGINE FAILURE sent 05/19/2010 for pictures regarding dust-outs. DIAGNOSIS: 1. Perform a compression test. Low compression is generally due to ring/piston/valve issues. High compression may be due to oil infiltration causing a hydraulic effect. 2. Major mechanical damage can also be caused by fuel, fuel injectors or "Up-rate kits or "programmers". Inspect vehicle for any device that adds more power, (fuel) which may damage the engine mechanically. Check for any aftermarket power enhancer or "box" or "downloader".Repairs of failures caused by these devices do not qualify for warranty coverage. 3. Inspect all air handling ducts and components. (See eFiles document). If dirt is found in the air handling components, further diagnostics may not be necessary. Engines with dirt detected on the "clean side" of air filter will not qualify for warranty coverage. 4. Inspect for aftermarket "cold air" performance air filter housing, duct work and filters. Again, Engines with dirt detected on the "clean side" of air filter will not qualify for warranty coverage. 5. Inspect cylinder bore(s) for cross-hatching and excessive piston ring ridge. The absence of cylinder bore cross-hatching MAY be one of the first signs of cylinder dust or dirt damage. Cylinder bore(s) for cross-hatching and excessive piston ring ridge may be inspected using a bore scope (if available), or cylinder head removal may be necessary. Contact your Business Center or Service and Parts Area Manager if dust out evidence is noticed or any type of tampering is suspected. Dirt carried in through the air handling system is typically funneled and concentrated to the end (1 & 6) cylinders*. Vertical scratches (broken rings) will follow. Generally, a properly maintained engine will have well defined hone marks visible beyond 100,000 miles. NOTE: Be aware of stains or marks in cylinder wall(s). Marks may follow the ring gap but have no depth or damage to the cylinder bore wall. These marks have a look similar to a "scored" cylinder, yet have no physical damage to the surface and will not cause any harm. These marks be checked by physically inspecting (scratching) the surface to detect if cylinder wall is damaged (grooved). 6. When inspecting the cylinder bore(s), compare cylinders # 1 & # 6 to the others. Cylinder honing (cross-hatching) performed in the Cummins engine manufacturing process is very aggressive. Engines that have dirt introduced will "polish out" this hone witness mark first and then start cutting or wearing down the cylinder walls which will create a ring ridge in the cylinder bore at the top of the bore. The absence of the cross-hatching ALONG WITH dirt found anywhere in the "clean-side" of the air intake system, is evidence of a dust-out condition. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Engine Systems/Exhaust Enhancements NUMBER: 18-020-10 GROUP: Vehicle Performance DATE: June 10, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-06, DATED DECEMBER 05, 2006 AND 18-001-09, DATED JANUARY 21, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. Either wiTECH OR StarMOBILE DESKTOP CLIENT can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. StarMOBILE® SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. SUBJECT: FLASH: Engine Systems And Exhaust Aftertreatment Systems Enhancements OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement based on customer use and mileage accumulation. This bulletin involves: ^ Selectively erasing and reprogramming the Engine Control Module (PCM), 2007 - 2010 MY. ^ Selectively erasing and reprogramming the Cab Compartment Node (CCN), 2007 & 2008 MY. ^ If CCN is updated; provide a Customer Information Sheet explaining the overhead display messages. ^ One of several software changes allows for "Net Zero" and "Net Reduction" which will cause noticeable changes in idle speeds. Customers should be informed of these changes. They are explained in DISCUSSION, Improvements that address erroneous MIL illumination for DTC P0106, P0191, P2262 and P2299 DTC's, (spelled out in DISCUSSION below). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. MODELS: 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) 2008 - 2010 (DM) Ram Truck (4500/5500 Cab Chassis) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). NOTE: For some 2007 MY vehicles, the ECM flash is addressed in Recall K01, Dated May, 2010. Where applicable. please use the Recall to update the ECM and this bulletin to update the CCN software. DISCUSSION: Cab chassis trucks equipped with a 6.7L Cummins diesel have a number of software improvements available. This latest Service Bulletin (SB) will include improvements to prevent erroneous Malfunction Indicator Lamp (MIL) illumination: ^ P000F - Fuel System Over Pressure Relief Valve Activated Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 8537 ^ P0087 - Fuel Rail Pressure Too Low ^ P0106 - Manifold Absolute Pressure Sensor Performance ^ P0191 - Fuel Rail Pressure Sensor Circuit Performance ^ P1011 - Fuel Pump Delivery Pressure Too Low ^ P2299 - Brake Pedal Position / Accelerator Pedal Position Incompatible ^ P2262 - Turbocharger Boost Pressure Not Detected - Mechanical Other updates will include the following operational and diagnostic improvements: 1. Stationary DeSoot is now available with this software. This feature works similar to pick up truck (DH/D1) models. 2. New DTC added for P2563 - Turbocharger Boost Control Position Sensor Performance. This DTC indicates diminished variable geometry turbocharger travel, which is resolved by replacing the turbocharger. Diagnosis and repair procedures for the DTC have been published in DTC-Based Diagnostics in TechConnect. 3. The latest PCM software includes a new extended idle feature to accommodate the extended idle times present in some duty cycles. This feature may help to reduce the accumulation of soot in the exhaust aftertreatment system when the engine is idling for an extended period of time. Briefly how this feature works: a. As needed, the engine enters an idling mode which dramatically reduces the rate of soot accumulation in the diesel particulate filter (called "Net Zero"). Further, under extended idle periods of 5 minutes or longer, the engine enters a mode which reduces the amount of soot accumulated in the diesel particulate filter (called "Net Reduction"). While in these modes, the idle speed increases to 900 RPM for a period of time. The idle speed may return to normal idle speed and then return to 900 RPM to repeat this cycle during very long idle periods. b. These modes occur automatically depending on the need to regenerate the DPF as long as the vehicle is not driven over 20 MPH or operated at high load. If the vehicle is driven over 20 MPH normal mobile desoot will occur automatically. 4. New scan tool driven fuel system diagnostic tests (same as previously released in the pick up) now available for cab chassis. DIAGNOSIS: 1. Using the scan tool, determine current software level of the PCM and CCN. Record on the repair order, for later use, the current PCM and CCN software level part numbers. Proceed to the next step. 2. Compare the current PCM software level part number with software available in the scantool. Determine if the current PCM software level part number, recorded in Step # 1, is programmable to a higher level. 3. Is the part number of the current PCM level software (recorded in Step # 1) at the latest level listed in the scan tool? a. If YES >> then the PCM DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. b. If NO >> then the PCM DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. 4. Is the vehicle a 2007 OR 2008 MY? a. Yes >>> Proceed to Step # 5. b. No >>> 2009 MY proceed to the REPAIR PROCEDURE as required. 5. Determine if the current CCN module level software part number, that was recorded earlier in Step # 1, is one of the following (or with a higher suffix): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 8538 a. 05172187AH (or higher) = 2007 DC (3500). b. 05172334AG (or higher) = 2008 DC (3500) / DM (3500/4500). c. 2009 & 2010 MY vehicles came equipped with proper CCN software. 6. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 5? a. If YES >>> then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. b. If NO >>> then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the REPAIR PROCEDURE as required. PARTS REQUIRED: REPAIR PROCEDURE; ECM MODULE REPROGRAM: NOTE: The wiTECH diagnostic application is the preferred method for flashing ECU's. Help using the wiTECH diagnostic application for flashing an ECU is available by selecting "Help" then "Help Contents" at the top of the wiTECH diagnostic application window. NOTE: The wiTECH software level must be at release 10.04 or higher to perform this procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. If required, as determined in DIAGNOSIS, above: reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > 8E - Electronic Control Modules >MODULE, Engine Control, Diesel > Service Information > Standard Procedure > PCM/ECM Programming - DIESEL. After PCM reprogramming, the following must be performed: a. Clear any DIG's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 3. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. 4. If required, as determined in DIAGNOSIS, above: reprogram the CCN using one of the following procedures, (based on scan tool use). 5. Was it determined in DIAGNOSIS, Step # 6 above, the CCN required updating? a. Yes >>> Proceed to appropriate CCN Module Reprogram Procedure Below, based on the scantool used. b. No >>> Repair is complete. NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 8539 NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.04 OR HIGHER. CCN MODULE REPROGRAM - USING wiTECH(R): 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id and "Password", then select "OK". 6. Select the "Next tab at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash" screen follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF position", remove the wiPOD(R) and battery charger from the vehicle. StarMOBILE(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident" flash file for statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 8540 b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step Se, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number (displayed at the end of the "Resident flash file for statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CUSTOMER INFORMATION SHEET INCLUDED: Please print the last page of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-020-10 > Jun > 10 > Engine Controls - Engine Systems/Exhaust Enhancements > Page 8541 Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "Exhaust Filter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required - See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test PROM - Programmable Read Only Memory: All Technical Service Bulletins Emissions - Vehicle Fails I/M Test NUMBER: 18-017-10 GROUP: Vehicle Performance DATE: May 15, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-038-09, DATED DECEMBER 19, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS REVISED BULLETIN WILL COVER FEDERAL EMISSIONS (EPA) CERTIFIED VEHICLES ONLY. VEHICLES EQUIPPED WITH CARB (CALIFORNIA) EMISSIONS HAVE BEEN REMOVED AND WILL NOW BE ADDRESSED IN RECALL K01, DATED MAY, 2010. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. WHENEVER A 2006-2007 MODULE IS REPROGRAMMED, THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. SUBJECT: Flash: Smog Check On-Board Diagnostic (OBD) Test OR Inspection & Maintenance Check Will Not Pass OVERVIEW: This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software. MODELS: 2006 DH Ram Truck (2500 Pick Up 5.9L) 2006 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DH Ram Truck (2500 Pick Up 5.9L) 2007 D1 Ram Truck (3500 Pick Up 5.9L) 2007 DC Ram Truck (3500 Cab Chassis 6.7L) NOTE: This bulletin applies to 2006 & 2007 vehicles equipped with a 5.9L Cummins Diesel Engine (sales code ETC or ETH) with Federal emissions (sales code NAA) built after January 1, 2006, or Cab Chassis equipped with a 6.7L Cummins Diesel Engine (sales code ETJ) built prior to January 11, 2007. NOTE: 2003, 2006 & 2007 5.9L (DR/DH/D1) & 2007 6.7L (DC) equipped vehicles with similar SYMPTOM/CONDITION as stated below equipped with California Emissions, (CARB Certified) (sales code NAE) will be addressed in Recall K01, dated May, 2010. SYMPTOM/CONDITION: The customer's vehicle may have difficulty passing a government mandated SMOG / Emissions test or and Inspection & Maintenance (I & M) test due to a scan tool reporting issue. These issues now effect diesel vehicles due to the recent expansion/change of SMOG/Emissions tests and/or Inspection & Maintenance (I & M) test programs in some locations, including California. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If any DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE 2006-2007 VEHICLE USING wiTECH or StarMOBILE(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-017-10 > May > 10 > Emissions - Vehicle Fails I/M Test > Page 8546 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical> Electronic Control Modules - Service Information> Module - Powertrain Control> Standard Procedures> PCM/ECM Programming - Diesel. After ECM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine, A/T Controls MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 8551 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 8552 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 PROM - Programmable Read Only Memory: All Technical Service Bulletins Computers/Controls CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 8557 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 8558 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 8559 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 8560 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC P2262 Set NUMBER: 09-002-09 GROUP: Engine DATE: May 23, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-001-08 and 11-002-08 BOTH DATED MAY21, 2008. THIS ISA COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE STANDALONE MODE OR StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: MIL Illumination Due to DIG P2262 - Revised Diagnosis and Repair Procedures OVERVIEW: This bulletin discusses revised diagnostic and repair procedures for DTC P2262 Turbocharger Boost Pressure Not Detected - Mechanical. Recent PGM calibration updates have improved the robustness to this DIG through updated diagnostic strategies. As a result, many events which have no adverse affects on drivability, emissions, or reliability will no longer set the P2262 fault. MODELS: 2007 - 2009 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicle equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DTC): P2262 - Turbocharger Boost Pressure Not Detected - Mechanical. As a result of recent PCM calibration updates, the proper repair for some P2262 faults is to just update the calibration, while others will require cleaning or replacing the turbocharger. Scan Tool software update 9.05 (and later) includes a P2262 diagnosis test for this purpose. This diagnostic test uses Freeze Frame data stored in the PCM and a dynamic turbocharger response test to determine the correct repair for each truck with DTC P2262. The new P2262 diagnosis test must be used prior to performing any of the following: ^ Clearing codes. ^ Updating the PCM. ^ Beginning the turbocharger repair. The test must be used with the key in the run position with the engine off, and with coolant temperature between 50°F and 180° F. The time required to run this test will vary with the calibration level of the truck, from a few seconds up to a couple minutes. This is normal operation for the test. NOTE: The P2262 diagnosis test MUST NOT be used after the repair is complete, as this test CANNOT be used to confirm the repair. Test results will be inaccurate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set > Page 8565 If the customer is experiencing MIL illumination due to Diagnostic Trouble Code (DTC): P2262 Turbocharger Boost Pressure Not Detected - Mechanical follow the revised diagnosis and repair procedures below. NOTE: Using the wiTECH Diagnostic Application for flashing an ECU is made available through the wiTECH Diagnostic Application. For instructions select the "HELP" tab on upper portion of the wiTECH window, then "HELP CONTENTS." This will open the Welcome to wiTECH Help screen were help topics can now selected. SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: While the wiTECH tool is the preferred method of testing and flashing, StarMOBILE desktop client, StarMOBILE standalone mode OR StarSCAN may also be used to perform this procedure. NOTE: Please read through this entire Service Bulletin to gain a full understanding before performing the procedure. DIAGNOSIS: 1. Connect the Scan Tool to the Diagnostic Link Connector (DLC). 2. Turn the ignition key to the RUN position, DO NOT start the engine. 3. From the "Vehicle View" screen on the Scan Tool select: a. "All DTC's button. 4. Record all Diagnostic Trouble Codes (DTC's) that are present in the PCM. NOTE: DO NOT erase DTC's or reprogram the PCM at this point. If P2262 is not present in the PCM due to clearing the faults or reprogramming the PCM, the P2262 diagnosis test in Scan Tool will not run. NOTE: It is IMPORTANT to record (capture) all DTC's present in the PCM prior to proceeding further with this diagnosis. Procedures later may cause all DTC's to be erased. 5. Is DTC P2262 present in the PCM? a. If YES >> Proceed to Step # 6. b. If NO >> Then STOP. This bulletin does not apply. 6. Confirm the engine coolant temperature is between 50°F and 180°F. 7. Perform the P2262 diagnostic test with wiTECH(R), From the "Vehicle View screen select: a. Select "PCM". b. Select "Systems Tests". c. Select "P2262 Fault Diagnosis Test Start". d. Follow on-screen prompts to complete test. NOTE: If you receive an error message from test, confirm that the Diagnostic Link Connector and turbocharger actuator harness connections are secure. Also confirm that engine coolant temperature is between 50°F and 180°F, then run the test again. 8. Based on the outcome of the P2262 diagnosis test, the Scan Tool will provide one of the following as the proper direction for the appropriate repair. Based on these results, refer to the detailed service information available in DealerCONNECT > TechCONNECT under: Service Info and complete Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set > Page 8566 the repair as directed; a. Update PCM Flash Calibration to the latest calibration. No repair required to the turbocharger. b. Clean the Turbocharger. c. Update PCM Flash Calibration to the latest calibration and Clean the Turbocharger. d. Replace the Turbocharger. e. Update PCM Flash Calibration to the latest calibration and Replace the Turbocharger. 9. Does the vehicle have other DTC's as recorded in Step # 4 above? a. Yes >> Follow appropriate diagnosis procedures or TSB related to diagnosis and repair of each fault. b. No >> Repair complete. NOTE: All other DTC's or symptoms MUST be addressed prior to returning the vehicle to the customer. NOTE: When/if replacing Turbocharger, p/n 68048234AA or 68031095AA must NOT be used on a D1/DH (Pick Up) models. Turbocharger p/n 68048234AA or 68031095AA are to be used on DA/DC/DM (Cab/Chassis) ONLY. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 8571 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 8572 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8577 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8578 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8579 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8580 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-035-07 > May > 07 > Engine Controls - A/T May Default To Neutral PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - A/T May Default To Neutral NUMBER: 18-035-07 GROUP: Vehicle Performance DATE: May 18, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 545RFE Transmission Defaults To Neutral OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2007 (HB/HG) Durango/Aspen 2007 (ND) Dakota NOTE: This bulletin applies to vehicles equipped with a 545RFE transmission (sale code DGQ) built on or before March 26, 2007 (MDH 0326XX). SYMPTOM/CONDITION: The transmission may default into neutral gear if the transmission gear selector is moved into "reverse gear range under certain operating conditions. The default into neutral gear is done to protect the transmission mechanical components from potential damage. New PCM software will monitor transmission hydraulic pressure and allow reverse gear engagement, if the transmission is in "reverse gear range and the transmission hydraulic pressure is sufficient to support reverse gear operation. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-035-07 > May > 07 > Engine Controls - A/T May Default To Neutral > Page 8585 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN® must be programmed with software release level 7.04 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN® for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (PCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-035-07 > May > 07 > Engine Controls - A/T May Default To Neutral > Page 8586 i. Highlight the listed calibration. j. Select "Update Controller". k. When the PCM update is complete, select "OK". NOTE: Due to the ECU programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Flash Reprogramming Abort Recovery NUMBER: 18-001-06 REV. A GROUP: Vehicle Performance DATE: July 12, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-001-06, DATED JANUARY II, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, YEARS AND A REVISED DISCUSSION ABOUT ABORTED FLASH REPROGRAMMING RECOVERY. SUBJECT: StarSCAN(R)/StarMOBILE(TM) Abort Recovery Procedures OVERVIEW: This Bulletin provides guidelines to minimize flash reprogramming problems and recovery procedure information for failed flash attempts. MODELS: **2007 (DC) Ram Cab & Chassis** 2006 - **2007** (DR/DH/D1) Ram Truck 2004 - **2007** (HB/HG) Durango/Aspen 2007 (JK) Wrangler **2007 (JS) Sebring** **2007 (KA) Nitro** 2006 - **2007** (KJ) Liberty/Cherokee 2005 - **2007** (LX/LE) 300/Magnum/Charger **2007 (MK) Compass** 2005 - **2007** (ND) Dakota **2007 (PM) Caliber** 2006 - **2007* (PT) PT Cruiser 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK/XH) Commander DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable. Replacing a module that is recoverable is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent unnecessary replacement of control modules. GENERAL: Flash Reprogramming is only authorized when programming a generic module or by a specific SERVICE ACTION (Service Bulletin/Recall/Rapid Response Transmittal/Advance Service Information). CAUTION: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery > Page 8591 When updating a module because of a Service Action, it is important to follow the steps outlined in the Repair Procedure section of the Service Action. Procedures may differ depending on the module that is being reprogrammed. Review the entire Service Action prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Action. COMMON CAUSES OF FLASH REPROGRAMMING ERRORS Interruptions, voltage problems, a variety of other outside interactions, and failure to follow the steps outlined in the Service Action can potentially interfere with the process. This document seeks to provide information to minimize problems associated with module flash reprogramming. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session, make sure you have the most current software installed in the scan tool (StarSCAN(R)/StarMOBILE(TM)). Refer to the current software release information available in TechCONNECT, under: Service Info > StarSCAN(R) and StarMOBILE(TM) Tools > Latest News > Select the most recent release number. The technician will be able to see the applicable version numbers. Often, because of multiple StarSCAN(R)/StarMOBILE(TM)s in the shop, not all devices will get updated in a timely manner. The installed StarSCAN(R)/StarMOBILE(TM) software version and scan tool operating system version, (Fig. 2), can be verified from the "Home" screen as follows: StarMOBILE Desktop Client ^ Select "Tool Menu". ^ Select "Version Information" Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery > Page 8592 StarSCAN ^ Select "Show Shortcuts" ^ Select "Tool Menu". ^ Select "Version Information" Typical Tool Menu (Fig. 1) NOTE: The StarSCAN also displays the version number on the right side of the blue header at the top of each screen. NOTE: To read the version on the StarMOBILE(TM), it must be connected and the application running or the user will receive "N/A" for the "System" value. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. It is a good practice to have dedicated cables devoted to "Flash ONLY". Always have a spare StarSCAN(R) CH9404 (vehicle) cable available. Always have a spare StarMOBILE(TM) CH9804 (vehicle) cable available (blue cable end). Diagnosing vehicle cable problems Inspect vehicle cable connectors for potential problems that might cause communication interruptions. Use the information available on DealerCONNECT under: ^ eSupport (above the "Marketing" tab) ^ Under "Knowledge Center" - select "Find Answers" ^ In the "Enter link, error message, or topic" area, type "561" ^ In the "Search By" area, select "Answer ID" ^ At the next screen, select the "StarSCAN Flash Lockup.pdf" link to access the information to diagnose suspect vehicle cable continuity. FLASH REPROGRAMMING PROBLEM PREVENTION ^ Follow the steps outlined in the Service Action. ^ Pay attention to the screen prompts displayed during the flash process. ^ Replace worn cables. ^ Verify the vehicle is equipped with a known good battery. ^ Ensure the battery charger charging rate provides approximately 13.2 - 13.8 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. **ABORTED FLASH REPROGRAMMING RECOVERY** ** The following steps may help recover a non-responsive module when the flash process is aborted or interrupted. 1. When the Flash ECU screen displays an Error Message, select OK. 2. Turn the ignition to "off" and power down the StarSCAN(R). 3. Turn the vehicle ignition to the "On" position. 4. Power on the StarSCAN®. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery > Page 8593 NOTE: If the technician was flashing a PCM, the tool may display "Unknown VIN". Disregard this. 5. Select (ECU) View. 6. Highlight the ECU that was being flashed. NOTE: The module may appear to be non-responsive. Highlight the module anyway. 7. Select More Options 8. Select ECU Flash 9. If the "Flash ECU" screen displays "Resident flash files for Part # XXXXX", the module should be recoverable. If the screen displays "No resident flash files found" the module is not recoverable. Does the Flash ECU screen display "No resident flash files found?" a. Yes >> The module must be replaced. b. No >> proceed to Step # 10. 10. Is a calibration file displayed on the StarSCAN(R)? a. Yes >> proceed to Step # 11. b. No >> Select "Browse For New File" and follow on screen instructions. Highlight the calibration that was previously chosen. Select "Download to Scantool". When the file is downloaded to the scantool, select "Back" and proceed to Step # 11. 11. Highlight the appropriate calibration. 12. Select "Update Controller" and follow the on screen instructions. 13. When the flash is complete, verify the "Resident flash file part number" matches the 'New PIN" of the appropriate calibration. 14. Proceed with the steps listed in the Service Bulletin to complete the service action.** NOTE: If after following the steps above, you are still having issues performing the flash reprogramming procedure using a specific StarSCAN(R)/StarMOBILE(R) it is suggested to contact SPX/Miller Special Tools for service. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-001-10 > Jul > 10 > Diesel Engine - Dust/Debris Ingestion/Power Upgrade Info > Page 8599 documents for pictures regarding dust-outs. NOTE: Canadian dealers can refer to Tech-Tip # 18 - CUMMINS DIESEL ENGINES FAILURES DO TO DIRTY AIR ENTERING THE INDUCTION SYSTEM - HOW TO INSPECT FOR SIGNS OF A "DUST OUT" ENGINE FAILURE sent 05/19/2010 for pictures regarding dust-outs. DIAGNOSIS: 1. Perform a compression test. Low compression is generally due to ring/piston/valve issues. High compression may be due to oil infiltration causing a hydraulic effect. 2. Major mechanical damage can also be caused by fuel, fuel injectors or "Up-rate kits or "programmers". Inspect vehicle for any device that adds more power, (fuel) which may damage the engine mechanically. Check for any aftermarket power enhancer or "box" or "downloader".Repairs of failures caused by these devices do not qualify for warranty coverage. 3. Inspect all air handling ducts and components. (See eFiles document). If dirt is found in the air handling components, further diagnostics may not be necessary. Engines with dirt detected on the "clean side" of air filter will not qualify for warranty coverage. 4. Inspect for aftermarket "cold air" performance air filter housing, duct work and filters. Again, Engines with dirt detected on the "clean side" of air filter will not qualify for warranty coverage. 5. Inspect cylinder bore(s) for cross-hatching and excessive piston ring ridge. The absence of cylinder bore cross-hatching MAY be one of the first signs of cylinder dust or dirt damage. Cylinder bore(s) for cross-hatching and excessive piston ring ridge may be inspected using a bore scope (if available), or cylinder head removal may be necessary. Contact your Business Center or Service and Parts Area Manager if dust out evidence is noticed or any type of tampering is suspected. Dirt carried in through the air handling system is typically funneled and concentrated to the end (1 & 6) cylinders*. Vertical scratches (broken rings) will follow. Generally, a properly maintained engine will have well defined hone marks visible beyond 100,000 miles. NOTE: Be aware of stains or marks in cylinder wall(s). Marks may follow the ring gap but have no depth or damage to the cylinder bore wall. These marks have a look similar to a "scored" cylinder, yet have no physical damage to the surface and will not cause any harm. These marks be checked by physically inspecting (scratching) the surface to detect if cylinder wall is damaged (grooved). 6. When inspecting the cylinder bore(s), compare cylinders # 1 & # 6 to the others. Cylinder honing (cross-hatching) performed in the Cummins engine manufacturing process is very aggressive. Engines that have dirt introduced will "polish out" this hone witness mark first and then start cutting or wearing down the cylinder walls which will create a ring ridge in the cylinder bore at the top of the bore. The absence of the cross-hatching ALONG WITH dirt found anywhere in the "clean-side" of the air intake system, is evidence of a dust-out condition. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > K01 > May > 10 > Recall - ECM Update For OBD Readiness Technical Service Bulletin # K01 Date: 100510 Recall - ECM Update For OBD Readiness May 2010 Dealer Service Instructions for: California Emissions Recall K01 Reprogram ECM OBD Readiness Effective immediately all repairs on involved vehicles are to be performed according to this notification. Service Bulletin 18-038-09 is no longer applicable for the involved vehicles only. Models 2003 (DR) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETC) and a California emission control system (sales code NAE). 2006-2007 (DH/D1) Dodge Ram Truck (2500/3500 series pickup) NOTE: This recall applies only to the above vehicles equipped with a 5.9L diesel engine (sales code ETH) and a California emission control system (sales code NAE). 2007 (DC) Dodge Ram Truck (3500 series cab chassis) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ) and a California emission control system (sales code NAE) built through January 5, 2007 (MDH010508). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process or GRS DealerCONNECT functions. Subject The Engine Control Module (ECM) on about 25,208 of the above vehicles may fail to accurately report diagnostic system information with some generic scan tools. This may cause the vehicle to be rejected or fail an Inspection/Maintenance Test (also known as a Smog Check). Repair The Engine Control Module (ECM) must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Part Number Description 04275086AB Authorized Modifications Label Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 8604 The special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the label plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 8605 To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: The DRBIII(R) must be used to perform this recall on 2003 Model Year (MY) vehicles. The 2003 MY procedure is found in Section D of the Service Procedure. Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall on 2006-2007 MY vehicles. This procedure must be performed with software release level 10.03 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 8606 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's" button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section E. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 8607 h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section E. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 8608 e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 10. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 9. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 10. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 11. Continue with Section E. Install Authorized Modification Label. D. Reprogram the ECM Using DRBIII(R): The DealerCONNECT System, DRBIII(R) (Diagnostic Readout Box scan tool), CH7000A flash cable and CH7035B data cable are required to perform this repair. Do not attempt to perform the flash procedure using an outdated CH7000/CH7001 flash cable. NOTE: Whenever a controller is reprogrammed, the software in the DRBIII scan tool must be programmed with the latest revision level available. NOTE: If the flash process is interrupted or aborted, the flash should be restarted and then follow the directions on the DRBIII scan tool. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 8609 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the DRBIII CH7000A flash cable from the DRBIII scan tool to the data link connector located inside the vehicle under the steering column. 3. Connect the CH7035B data cable from the DealerCONNECT machine to the MDS port on the DRBIII scan tool. 4. Place the vehicle's ignition key in the "RUN" position. 5. From the DealerCONNECT "WELCOME" screen, enter your "User I.D.," "Password" and "Dealer Code". 6. From the DealerCONNECT "HOME PAGE" select the "SERVICE" tab. 7. From the "SERVICE" tab screen select "TechTOOLS". 8. If the DRBIII scan tool does not "Auto Connect" select # 2 on the DRBIII key pad "Connect to TechCONNECT". 9. After the "Auto Connect" process is complete, select "READ PART NUMBER(S) FROM VEHICLE" on the TechCONNECT screen. 10. Continue following the TechCONNECT on-screen instructions. 11. Select the applicable update calibration. 12. Select the "DRBIII" button located at the bottom of the TechCONNECT monitor screen. 13. Select the "DOWNLOAD / UPDATE" button located next to the "DRBIII" button. NOTE: The system software will automatically download to the DRBIII scan tool. 14. After the software download to the DRBIII scan tool is complete, close the "DOWNLOAD / UPDATE PROGRESS" window. 15. Disconnect the DRBIII scan tool from the TechCONNECT CH7035B data cable. 16. Select # 1 "RETURN TO NORMAL MODE" on the DRBIII scan tool. 17. Use the following procedure to download the flash from the DRBIII scan tool to the vehicle. a. Select # 7 "VEHICLE FLASH" on the DRBIII scan tool. b. Follow the directions displayed on the DRBIII scan tool screen. c. After the reprogramming is complete, record the new module part number displayed on the DRBIII scan tool screen. d. Press the "PAGE BACK" button on the DRBIII scan tool. 18. Due to the ECM flash procedure, Diagnostic Trouble Codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS, ORC) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules, record the trouble codes, and erase the trouble codes using the following procedure: a. Turn the vehicle's ignition key to the "RUN" position. b. From the DRBIII scan tool Main Menu select # 1 "DRBIII Stand-Alone". c. From the DRBIII scan tool Stand-Alone menu select # 3 "Vehicle Module Scan". d. From the DRBIII scan tool Vehicle Module Scan menu select # 1 "1998 - 2005 Module Scan". e. Select "YES" on the DRBIII scan tool key pad to scan for DTC's. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 8610 f. Follow the instructions on the DRBIII scan tool screen. g. Once the scanning process is complete, the DRBIII scan tool will display a list of all the modules. Modules on the list that have an asterisk next to them have DTC's that need to be cleared. h. Select the module that needs to have the DTC's cleared and follow the instructions on the DRBIII scan tool screen to clear the DTC's. i. Turn the vehicle's ignition key to the "OFF" position. NOTE: Erase any DTC's in the ECM only after all other modules have had their DTC's erased. 19. Disconnect the DRBIII scan tool from the vehicle. 20. Turn off the battery charger and disconnect it from the vehicle. 21. Continue with Section E. Install Authorized Modification Label. E. Install the Authorized Modifications Label: 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > K01 > May > 10 > Recall - ECM Update For OBD Readiness > Page 8611 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 8616 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 8617 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 8618 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 8619 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 8620 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 8621 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 8622 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 8627 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 8628 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 8629 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 8630 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 8631 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 8632 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 8633 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery > Page 8638 When updating a module because of a Service Action, it is important to follow the steps outlined in the Repair Procedure section of the Service Action. Procedures may differ depending on the module that is being reprogrammed. Review the entire Service Action prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Action. COMMON CAUSES OF FLASH REPROGRAMMING ERRORS Interruptions, voltage problems, a variety of other outside interactions, and failure to follow the steps outlined in the Service Action can potentially interfere with the process. This document seeks to provide information to minimize problems associated with module flash reprogramming. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session, make sure you have the most current software installed in the scan tool (StarSCAN(R)/StarMOBILE(TM)). Refer to the current software release information available in TechCONNECT, under: Service Info > StarSCAN(R) and StarMOBILE(TM) Tools > Latest News > Select the most recent release number. The technician will be able to see the applicable version numbers. Often, because of multiple StarSCAN(R)/StarMOBILE(TM)s in the shop, not all devices will get updated in a timely manner. The installed StarSCAN(R)/StarMOBILE(TM) software version and scan tool operating system version, (Fig. 2), can be verified from the "Home" screen as follows: StarMOBILE Desktop Client ^ Select "Tool Menu". ^ Select "Version Information" Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery > Page 8639 StarSCAN ^ Select "Show Shortcuts" ^ Select "Tool Menu". ^ Select "Version Information" Typical Tool Menu (Fig. 1) NOTE: The StarSCAN also displays the version number on the right side of the blue header at the top of each screen. NOTE: To read the version on the StarMOBILE(TM), it must be connected and the application running or the user will receive "N/A" for the "System" value. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. It is a good practice to have dedicated cables devoted to "Flash ONLY". Always have a spare StarSCAN(R) CH9404 (vehicle) cable available. Always have a spare StarMOBILE(TM) CH9804 (vehicle) cable available (blue cable end). Diagnosing vehicle cable problems Inspect vehicle cable connectors for potential problems that might cause communication interruptions. Use the information available on DealerCONNECT under: ^ eSupport (above the "Marketing" tab) ^ Under "Knowledge Center" - select "Find Answers" ^ In the "Enter link, error message, or topic" area, type "561" ^ In the "Search By" area, select "Answer ID" ^ At the next screen, select the "StarSCAN Flash Lockup.pdf" link to access the information to diagnose suspect vehicle cable continuity. FLASH REPROGRAMMING PROBLEM PREVENTION ^ Follow the steps outlined in the Service Action. ^ Pay attention to the screen prompts displayed during the flash process. ^ Replace worn cables. ^ Verify the vehicle is equipped with a known good battery. ^ Ensure the battery charger charging rate provides approximately 13.2 - 13.8 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. **ABORTED FLASH REPROGRAMMING RECOVERY** ** The following steps may help recover a non-responsive module when the flash process is aborted or interrupted. 1. When the Flash ECU screen displays an Error Message, select OK. 2. Turn the ignition to "off" and power down the StarSCAN(R). 3. Turn the vehicle ignition to the "On" position. 4. Power on the StarSCAN®. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery > Page 8640 NOTE: If the technician was flashing a PCM, the tool may display "Unknown VIN". Disregard this. 5. Select (ECU) View. 6. Highlight the ECU that was being flashed. NOTE: The module may appear to be non-responsive. Highlight the module anyway. 7. Select More Options 8. Select ECU Flash 9. If the "Flash ECU" screen displays "Resident flash files for Part # XXXXX", the module should be recoverable. If the screen displays "No resident flash files found" the module is not recoverable. Does the Flash ECU screen display "No resident flash files found?" a. Yes >> The module must be replaced. b. No >> proceed to Step # 10. 10. Is a calibration file displayed on the StarSCAN(R)? a. Yes >> proceed to Step # 11. b. No >> Select "Browse For New File" and follow on screen instructions. Highlight the calibration that was previously chosen. Select "Download to Scantool". When the file is downloaded to the scantool, select "Back" and proceed to Step # 11. 11. Highlight the appropriate calibration. 12. Select "Update Controller" and follow the on screen instructions. 13. When the flash is complete, verify the "Resident flash file part number" matches the 'New PIN" of the appropriate calibration. 14. Proceed with the steps listed in the Service Bulletin to complete the service action.** NOTE: If after following the steps above, you are still having issues performing the flash reprogramming procedure using a specific StarSCAN(R)/StarMOBILE(R) it is suggested to contact SPX/Miller Special Tools for service. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Description Overdrive Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Description > Page 8648 Overdrive Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > Removal Overdrive Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > Removal > Page 8651 Overdrive Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid Pressure Regulating Solenoid: Locations Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8656 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8657 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8658 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8659 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8660 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8661 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8662 Pressure Regulating Solenoid: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8663 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid Pressure Regulating Solenoid: Diagrams Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8666 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8667 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8668 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8669 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8670 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8671 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8672 Pressure Regulating Solenoid: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8673 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Description Pressure Regulating Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Description > Page 8676 Pressure Regulating Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Removal Pressure Regulating Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Removal > Page 8679 Pressure Regulating Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Component ID: 440 Component : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Connector: Name : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Color : BLACK # of pins : 2 Pin Description Circuit 1 BTSI SOLENOID CONTROL K32 18DB/YL 2 GROUND Z101 18BK/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 8683 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 8684 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 8685 Shift Interlock Solenoid: Diagrams Component ID: 440 Component : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Connector: Name : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Color : BLACK # of pins : 2 Pin Description Circuit 1 BTSI SOLENOID CONTROL K32 18DB/YL 2 GROUND Z101 18BK/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 8686 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 8687 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid Shift Solenoid: Locations Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8692 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8693 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8694 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8695 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8696 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8697 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8698 Shift Solenoid: Locations Assembly-Transmission Solenoid/Pressure Switch Component ID: 17 Component : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH Color : LT. BROWN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 OD SOLENOID CONTROL T60 20YL/GY 2 UD CONTROL T59 20YL/LB 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 2-4 SOLENOID CONTROL T19 18YL/DB 5 2-4 PRESSURE SWITCH SENSE T47 18YL/DG 6 OD PRESSURE SIGNAL T9 20DG/TN 7 L/R CONTROL T20 20DG/WT 8-9-10 L/R PRESSURE SIGNAL T50 20YL/TN Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8699 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8700 Shift Solenoid: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8701 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid Shift Solenoid: Diagrams Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8704 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8705 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8706 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8707 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8708 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8709 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8710 Shift Solenoid: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8711 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation > Description Shift Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation > Description > Page 8714 Shift Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Removal Shift Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Removal > Page 8717 Shift Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Description and Operation Throttle Valve Solenoid: Description and Operation DESCRIPTION On vehicles equipped with a Cummins diesel engine, the transmission throttle valve cable has been replace by the transmission throttle valve actuator (TTVA). The TTVA consists of an electric DC motor, two potentiometers, and a gear drive system. The TTVA is mechanically connected to the transmission throttle valve in the valve body by the "D" shaped opening in the bottom of the TTVA shaft. Changes in the TTVA position are therefore transferred to the throttle valve and cause changes in the transmission throttle pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Description and Operation > Page 8721 Throttle Valve Solenoid: Adjustments ADJUSTMENT The Transmission Throttle Valve Actuator (TTVA) does not require any mechanical adjustments. All changes in throttle valve position are controlled by the Engine Control Module (ECM). The TTVA does require an initialization period after the actuator has been removed or replaced. After the actuator has been removed or replaced, move the ignition to the ON position for thirty (30) seconds. This will allow the ECM sufficient time to perform the internal calibration procedures to learn the TTVA's current "zero" position. Once this is done, check the ECM for diagnostic trouble codes (DTCs). If no DTCs are set relating to the TTVA, the TTVA is fully calibrated and ready for use. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Service and Repair > Removal Throttle Valve Solenoid: Service and Repair Removal REMOVAL 1. Remove the bolts (2) holding the transmission throttle valve actuator (TTVA) (1) to the transmission case. 2. Allow the TTVA (1) to rotate clockwise away from the transmission. 3. Remove the wiring connector (2) from the TTVA (1). 4. Lift the TTVA (1) straight upward and off the throttle valve shaft (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Service and Repair > Removal > Page 8724 Throttle Valve Solenoid: Service and Repair Installation INSTALLATION 1. Position the transmission throttle valve actuator (TTVA) (1) over the throttle valve shaft (3). 2. Align the D-shaped opening in the bottom of the TTVA to the throttle valve shaft and install the TTVA onto the shaft. 3. Install the wiring connector (2) to the TTVA (1). 4. Rotate the TTVA (1) to the transmission case and install the bolts (2) to hold the TTVA to the transmission. 5. Tighten the bolts to 8.5 Nm (75 in.lbs.). 6. Initialize the TTVA. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal Actuator: Service and Repair Removal REMOVAL 1. Remove actuator wiring connector. 2. Remove actuator (1) bolts (2). 3. Remove actuator (1) from disconnect pocket (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal > Page 8730 Actuator: Service and Repair Installation INSTALLATION 1. Clean actuator (1) sealing surface and install new gasket (2) if necessary. 2. Align actuator shift fork (1) with disconnect collar (2) and install actuator on disconnect pocket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal > Page 8731 3. Install actuator (1) bolts (2) and tighten to 27 Nm (20 ft. lbs.). 4. Install disconnect actuator wiring connector. 5. Verify differential fluid level and add fluid if necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front Solenoid: Locations Module-Axle Disconnect-Front Component ID: 200 Component : MODULE-AXLE DISCONNECT-FRONT Connector: Name : MODULE-AXLE DISCONNECT-FRONT Color : DK. GRAY # of pins : 4 Qualifier : (LD 4WD) Pin Description Circuit 1 GROUND Z906 20BK 2 FRONT AXLE LOCK CONTROL G304 20VT/DB 3 FUSED B(+) A880 20DB/RD 4 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 35 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 8736 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 8737 Solenoid: Locations Solenoid-Locker-Front Component ID: 442 Component : SOLENOID-LOCKER-FRONT Connector: Name : SOLENOID-LOCKER-FRONT Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 FRONT LOCKER SOURCE T520 16YL/OR 2 LOCKER SENSOR SUPPLY T521 18YL/BK 3 FRONT LOCKER SENSOR SENSE T522 18YL/LB 4 FRONT LOCKER RETURN T524 16YL/LG Component Location - 36 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 8738 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 8739 Solenoid: Locations Solenoid-Locker-Rear Component ID: 443 Component : SOLENOID-LOCKER-REAR Connector: Name : SOLENOID-LOCKER-REAR Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 REAR LOCKER SOURCE T526 16YL/WT 2 LOCKER SENSOR SUPPLY T523 18YL/BK 3 REAR LOCKER SENSOR SENSE T527 18YL/TN 4 REAR LOCKER RETURN T528 16YL/GY Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 8740 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front Solenoid: Diagrams Module-Axle Disconnect-Front Component ID: 200 Component : MODULE-AXLE DISCONNECT-FRONT Connector: Name : MODULE-AXLE DISCONNECT-FRONT Color : DK. GRAY # of pins : 4 Qualifier : (LD 4WD) Pin Description Circuit 1 GROUND Z906 20BK 2 FRONT AXLE LOCK CONTROL G304 20VT/DB 3 FUSED B(+) A880 20DB/RD 4 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 35 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 8743 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 8744 Solenoid: Diagrams Solenoid-Locker-Front Component ID: 442 Component : SOLENOID-LOCKER-FRONT Connector: Name : SOLENOID-LOCKER-FRONT Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 FRONT LOCKER SOURCE T520 16YL/OR 2 LOCKER SENSOR SUPPLY T521 18YL/BK 3 FRONT LOCKER SENSOR SENSE T522 18YL/LB 4 FRONT LOCKER RETURN T524 16YL/LG Component Location - 36 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 8745 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 8746 Solenoid: Diagrams Solenoid-Locker-Rear Component ID: 443 Component : SOLENOID-LOCKER-REAR Connector: Name : SOLENOID-LOCKER-REAR Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 REAR LOCKER SOURCE T526 16YL/WT 2 LOCKER SENSOR SUPPLY T523 18YL/BK 3 REAR LOCKER SENSOR SENSE T527 18YL/TN 4 REAR LOCKER RETURN T528 16YL/GY Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 8747 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations Transfer Case Actuator: Locations Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 8752 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 8753 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 8754 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 8755 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 8756 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 8757 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 8758 Transfer Case Actuator: Diagrams Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 8759 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 8760 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 8761 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 8762 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 8763 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 8764 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case Transfer Case Actuator: Description and Operation NV243 Transfer Case Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 8767 torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 8768 Transfer Case Actuator: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 8769 Transfer Case Actuator: Description and Operation NV246 Transfer Case Description DESCRIPTION The shift motor consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Front Control Module (FCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 8770 Transfer Case Actuator: Description and Operation NV273 Transfer Case Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case Transfer Case Actuator: Service and Repair NV243 Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. Installation INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 8773 Transfer Case Actuator: Service and Repair NV244 GENII Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. Installation INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 8774 Transfer Case Actuator: Service and Repair NV246 Transfer Case Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Remove the front propeller shaft. 3. Disengage the wiring connectors from the shift motor and mode sensor. 4. Remove the bolts (1) holding the shift motor and mode sensor assembly (2) onto the transfer case. 5. Separate the shift motor and mode sensor assembly (1) from the transfer case. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 8775 6. Remove the shift motor isolator (1) from the transfer case (2). Installation INSTALLATION 1. Install the shift motor isolator (1) onto the transfer case (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 8776 NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Install the shift motor and mode sensor assembly (1) onto the transfer case. CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 3. Install the bolts (1) to hold the shift motor and mode sensor assembly (2) onto the transfer case. Tighten the bolts to 23.5 Nm (17 ft.lbs.). 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Install the front propeller shaft. 6. Refill the transfer case as necessary with the correct fluid for the application. 7. Lower vehicle and verify transfer case operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 8777 Transfer Case Actuator: Service and Repair NV273 Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. Installation INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Description Overdrive Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Description > Page 8784 Overdrive Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > Removal Overdrive Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > Removal > Page 8787 Overdrive Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid Pressure Regulating Solenoid: Locations Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8792 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8793 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8794 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8795 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8796 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8797 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8798 Pressure Regulating Solenoid: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8799 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid Pressure Regulating Solenoid: Diagrams Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8802 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8803 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8804 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8805 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8806 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8807 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8808 Pressure Regulating Solenoid: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8809 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Description Pressure Regulating Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Description > Page 8812 Pressure Regulating Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Removal Pressure Regulating Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Removal > Page 8815 Pressure Regulating Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Component ID: 440 Component : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Connector: Name : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Color : BLACK # of pins : 2 Pin Description Circuit 1 BTSI SOLENOID CONTROL K32 18DB/YL 2 GROUND Z101 18BK/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 8819 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 8820 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 8821 Shift Interlock Solenoid: Diagrams Component ID: 440 Component : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Connector: Name : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Color : BLACK # of pins : 2 Pin Description Circuit 1 BTSI SOLENOID CONTROL K32 18DB/YL 2 GROUND Z101 18BK/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 8822 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 8823 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid Shift Solenoid: Locations Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8828 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8829 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8830 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8831 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8832 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8833 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8834 Shift Solenoid: Locations Assembly-Transmission Solenoid/Pressure Switch Component ID: 17 Component : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH Color : LT. BROWN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 OD SOLENOID CONTROL T60 20YL/GY 2 UD CONTROL T59 20YL/LB 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 2-4 SOLENOID CONTROL T19 18YL/DB 5 2-4 PRESSURE SWITCH SENSE T47 18YL/DG 6 OD PRESSURE SIGNAL T9 20DG/TN 7 L/R CONTROL T20 20DG/WT 8-9-10 L/R PRESSURE SIGNAL T50 20YL/TN Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8835 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8836 Shift Solenoid: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8837 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid Shift Solenoid: Diagrams Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8840 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8841 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8842 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8843 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8844 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8845 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8846 Shift Solenoid: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8847 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Description and Operation > Description Shift Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Description and Operation > Description > Page 8850 Shift Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Removal Shift Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Removal > Page 8853 Shift Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Throttle Valve Solenoid, A/T > Component Information > Description and Operation Throttle Valve Solenoid: Description and Operation DESCRIPTION On vehicles equipped with a Cummins diesel engine, the transmission throttle valve cable has been replace by the transmission throttle valve actuator (TTVA). The TTVA consists of an electric DC motor, two potentiometers, and a gear drive system. The TTVA is mechanically connected to the transmission throttle valve in the valve body by the "D" shaped opening in the bottom of the TTVA shaft. Changes in the TTVA position are therefore transferred to the throttle valve and cause changes in the transmission throttle pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Throttle Valve Solenoid, A/T > Component Information > Description and Operation > Page 8857 Throttle Valve Solenoid: Adjustments ADJUSTMENT The Transmission Throttle Valve Actuator (TTVA) does not require any mechanical adjustments. All changes in throttle valve position are controlled by the Engine Control Module (ECM). The TTVA does require an initialization period after the actuator has been removed or replaced. After the actuator has been removed or replaced, move the ignition to the ON position for thirty (30) seconds. This will allow the ECM sufficient time to perform the internal calibration procedures to learn the TTVA's current "zero" position. Once this is done, check the ECM for diagnostic trouble codes (DTCs). If no DTCs are set relating to the TTVA, the TTVA is fully calibrated and ready for use. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Throttle Valve Solenoid, A/T > Component Information > Service and Repair > Removal Throttle Valve Solenoid: Service and Repair Removal REMOVAL 1. Remove the bolts (2) holding the transmission throttle valve actuator (TTVA) (1) to the transmission case. 2. Allow the TTVA (1) to rotate clockwise away from the transmission. 3. Remove the wiring connector (2) from the TTVA (1). 4. Lift the TTVA (1) straight upward and off the throttle valve shaft (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Throttle Valve Solenoid, A/T > Component Information > Service and Repair > Removal > Page 8860 Throttle Valve Solenoid: Service and Repair Installation INSTALLATION 1. Position the transmission throttle valve actuator (TTVA) (1) over the throttle valve shaft (3). 2. Align the D-shaped opening in the bottom of the TTVA to the throttle valve shaft and install the TTVA onto the shaft. 3. Install the wiring connector (2) to the TTVA (1). 4. Rotate the TTVA (1) to the transmission case and install the bolts (2) to hold the TTVA to the transmission. 5. Tighten the bolts to 8.5 Nm (75 in.lbs.). 6. Initialize the TTVA. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Accumulator: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The valve body consists of a cast aluminum valve body, a separator plate, and transfer plate. The valve body contains valves and check balls that control fluid delivery to the torque converter clutch, bands, and frictional clutches. The valve body contains the following components. By adjusting the spring pressure acting on the regulator valve, transmission line pressure can be adjusted. Upper Housing Control Valve Locations - Regulator valve (2) - Switch valve (3) - Regulator valve spring (4) - Kickdown valve (5) - Kickdown detent (6) - Throttle valve and spring (7) - Manual valve (8) - 1-2 Governor plug (9) - Throttle pressure plug (11) - 2-3 Governor plug (12) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8865 - Shuttle valve primary spring (13) Shuttle and Boost Valve Locations - Boost Valve (3) - Boost valve plug (4) - Shuttle valve (9) - Shuttle valve throttle plug (12) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8866 Upper Housing Shift Valve and Pressure Plug Locations - 1-2 shift valve (2) - 1-2 control valve - 2-3 shift valve - 2-3 throttle plug - Throttle pressure plug - Limit valve and spring Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8867 Lower Housing Shift Valves and Springs - 3-4 shift valve - 3-4 timing valve - 3-4 quick fill valve - 3-4 accumulator - Converter clutch lock-up valve - Converter clutch lock-up timing valve Operation OPERATION NOTE: Refer to the Hydraulic Schematics for a visual aid in determining valve location, operation and design. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8868 CHECK BALLS REGULATOR VALVE Regulator Valve in Park Position The pressure regulator valve is needed to control the hydraulic pressure within the system and reduce the amount of heat produced in the fluid. The pressure regulator valve is located in the valve body near the manual valve. The pressure regulator valve train controls the maximum pressure in the lines by metering the dumping of fluid back into the sump. Regulated pressure is referred to as "line pressure." The regulator valve has a spring on one end that pushes the valve to the left. This closes a dump (vent) that is used to lower pressure. The closing of the dump will cause the oil pressure to increase. Oil pressure on the opposite end of the valve pushes the valve to the right, opening the dump and lowering oil pressure. The result is spring pressure working against oil pressure to maintain the oil at specific pressures. With the engine running, fluid flows from the pump to the pressure regulator valve, manual valve, and the interconnected circuits. As fluid is sent through passages to the regulator valve, the pressure pushes the valve to the right against the large spring. It is also sent to the reaction areas on the left side of the throttle pressure plug and the line pressure plug. With the gear selector in the PARK position, fluid recirculates through the regulator and manual valves back to the sump. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8869 Regulator Valve in Neutral Position Meanwhile, the torque converter is filled slowly. In all other gear positions, fluid flows between two right side lands to the switch valve and torque converter. At low pump speeds, the flow is controlled by the pressure valve groove to reduce pressure to the torque converter. After the torque converter and switch valve fill with fluid, the switch valve becomes the controlling metering device for torque converter pressure. The regulator valve then begins to control the line pressure for the other transmission circuits. The balance of the fluid pressure pushing the valve to the right and the spring pressure pushing to the left determines the size of the metering passage at land #2 (land #1 being at the far right of the valve in the diagram). As fluid leaks past the land, it moves into a groove connected to the filter or sump. As the land meters the fluid to the sump, it causes the pressure to reduce and the spring decreases the size of the metering passage. When the size of the metering passage is reduced, the pressure rises again and the size of the land is increased again. Pressure is regulated by this constant balance of hydraulic and spring pressure. Regulator Valve in Drive Position The metering at land #2 establishes the line pressure throughout the transmission. It is varied according to changes in throttle position and the transmission's internal condition within a range of 57-94 psi (except in REVERSE). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8870 Regulator Valve in Reverse Position The regulated line pressure in REVERSE is held at much higher pressures than in the other gear positions: 145-280 psi. The higher pressure for REVERSE is achieved by the manual valve blocking the supply of line pressure to the reaction area left of land #4. With this pressure blocked, there is less area for pressure to act on to balance the force of the spring on the right. This allows line pressure to push the valve train to the right, reducing the amount of fluid returned to the pump's inlet, increasing line pressure. KICKDOWN VALVE Kickdown Valve - Wide Open Throttle When the throttle valve is as far over to the left as it can go, the maximum line pressure possible will enter the throttle pressure circuit. In this case, throttle pressure will equal line pressure. With the kickdown valve pushed into the bore as far as it will go, fluid initially flows through the annular Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8871 groove of the 2-3 shift valve (which will be in the direct drive position to the right). After passing the annular groove, the fluid is routed to the spring end of the 2-3 shift valve. Fluid pressure reacting on the area of land #1 overcomes governor pressure, downshifting the 2-3 shift valve into the kickdown, or second gear stage of operation. The valve is held in the kickdown position by throttle pressure routed from a seated check ball (#2). Again, if vehicle speed is low enough, throttle pressure will also push the 1-2 shift valve left to seat its governor plug, and downshift to drive breakaway. KICKDOWN LIMIT VALVE Kickdown Limit Valve - Low Speeds The purpose of the limit valve is to prevent a 3-2 downshift at higher speeds when a part-throttle downshift is not desirable. At these higher speeds only a full throttle 3-2 downshift will occur. At low road speeds the limit valve does not come into play and does not affect the downshifts. Kickdown Limit Valve - High Speeds As the vehicle's speed increases, the governor pressure also increases. The increased governor pressure acts on the reaction area of the bottom land of the limit valve overcoming the spring force trying to push the valve toward the bottom of its bore. This pushes the valve upward against the spring and bottoms the valve against the top of the housing. With the valve bottomed against the housing, the throttle pressure supplied to the valve will be closed off by the bottom land of the limit valve. When the supply of throttle pressure has been shut off, the 3-2 part throttle downshift plug becomes inoperative, because no pressure is acting on its reaction area. 1-2 SHIFT VALVE 1-2 Shift Valve - Before Shift Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8872 The 1-2 shift valve assembly, or mechanism, consists of: the 1-2 shift valve, governor plug, and a spring on the end of the valve. After the manual valve has been placed into a forward gear range, line pressure is directed to the 1-2 shift valve. As the throttle is depressed, throttle pressure is applied to the right side of the 1-2 shift valve assembly. With throttle pressure applied to the right side of the valve, there is now both spring pressure and throttle pressure acting on the valve, holding it against the governor plug. As the vehicle begins to move and build speed, governor pressure is created and is applied to the left of the valve at the governor plug. 1-2 Shift Valve - After Shift When governor pressure builds to a point where it can overcome the combined force of the spring and throttle pressure on the other side of the valve, the valve will begin to move over to the right. As the valve moves to the right, the middle land of the valve will close off the circuit supplying the throttle pressure to the right side of the valve. When the throttle pressure is closed off, the valve will move even farther to the right, allowing line pressure to enter another circuit and energize the front servo, applying the front band. The governor plug serves a dual purpose: - It allows the shift valves to move either left or right, allowing both upshifts and downshifts. - When in a manual selection position, it will be hydraulically "blocked" into position so no upshift can occur. The physical blocking of the upshift while in the manual "1" position is accomplished by the directing of line pressure between both lands of the governor plug. The line pressure reacts against the larger land of the plug, pushing the plug back against the end plate overcoming governor pressure. With the combination of the line pressure and spring pressure, the valve cannot move, preventing any upshift. 1-2 SHIFT CONTROL VALVE 1-2 Shift Control Valve It contains a valve with four lands and a spring. It is used as both a "relay" and "balanced" valve. The valve has two specific operations: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8873 - Aid in quality of the 1-2 upshift. - Aid in the quality and timing of the 3-2 kickdown ranges. When the manual valve is set to the DRIVE position and the transmission is in the first or second gear range, 1-2 shift control or "modulated throttle pressure" is supplied to the middle of the accumulator piston by the 1-2 shift control valve. During the 1-2 upshift, this pressure is used to control the kickdown servo apply pressure that is needed to apply the kickdown and accumulator pistons. Thus, the 1-2 shift point is "cushioned" and the quality is improved. During a WOT kickdown, kickdown pressure is applied between the kickdown valve and the 1-2 shift control valve. This additional pressure is directed to the 1-2 shift control's spring cavity, adding to the spring load on the valve. The result of this increased "modulated" throttle pressure is a firmer WOT upshift. 2-3 SHIFT VALVE 2-3 Shift Valve - Before Shift The 2-3 shift valve mechanism consists of the 2-3 shift valve, governor plug and spring, and a throttle plug. After the 1-2 shift valve has completed its operation and applied the front band, line pressure is directed to the 2-3 shift valve through the connecting passages from the 1-2 shift valve. The line pressure will then dead-end at land #2 until the 2-3 valve is ready to make its shift. Now that the vehicle is in motion and under acceleration, there is throttle pressure being applied to the spring side of the valve and between lands #3 and #4. 2-3 Shift Valve - After Shift As vehicle speed increases, governor pressure increases proportionately, until it becomes great enough to overcome the combined throttle and spring pressure on the right side of the valve. Since the throttle pressure end of the 2-3 shift valve is larger in diameter than the 1-2 shift valve, the 2-3 shift will always happen at a greater speed than the 1-2 shift. When this happens, the governor plug is forced against the shift valve moving it to the right. The shift valve causes land #4 to close the passage supplying throttle pressure to the 2-3 shift valve. Without throttle pressure present in the circuit now, the Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8874 governor plug will push the valve over far enough to bottom the valve in its bore. This allows land #2 to direct line pressure to the front clutch. After the shift, line pressure is directed to the release side of the kickdown servo. This releases the front band and applies the front clutch, shifting into third gear or direct drive. The rear clutch remains applied, as it has been in the other gears. During a manual "1" or manual "2" gear selection, line pressure is sent between the two lands of the 2-3 governor plug. This line pressure at the governor plug locks the shift valve into the second gear position, preventing an upshift into direct drive. The theory for the blocking of the valve is the same as that of the 1-2 shift valve. If the manual "2" or manual "1" gear position is selected from the drive position, the PCM will control the timing of the downshift by targeting for a high governor pressure. When a safe vehicle speed is reached, the PCM will switch to its normal control governor curve and the downshift will occur. 3-4 SHIFT VALVE 3-4 Shift Valve Before Shift The PCM energizes the overdrive solenoid during the 3-4 upshift. This causes the solenoid check ball to close the vent port allowing line pressure from the 2-3 shift valve to act directly on the 3-4 upshift valve. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8875 3-4 Shift Valve After Shift Line pressure on the 3-4 shift valve overcomes valve spring pressure moving the valve to the upshift position. This action exposes the feed passages to the 3-4 timing valve, 3-4 quick fill valve, 3-4 accumulator, and ultimately to the overdrive piston. 3-4 TIMING VALVE 3-4 Shift Valve After Shift The 3-4 timing valve is moved by line pressure coming through the 3-4 shift valve or the converter clutch valve. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8876 3-4 Shift Valve Before Shift After the shift, the timing valve holds the 2-3 shift valve in an upshift position. The purpose is to prevent the 2-3 valve from downshifting while either the overdrive clutch or converter clutch is applied. 3-4 QUICK FILL VALVE 3-4 Shift Valve Before Shift The 3-4 quick fill valve provides faster engagement of the overdrive clutch during 3-4 upshifts. The valve temporarily bypasses the clutch piston feed orifice at the start of a 3-4 upshift. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8877 3-4 Shift Valve After Shift This exposes a larger passage into the piston retainer resulting in a much faster clutch fill and apply sequence. The quick fill valve does not bypass the regular clutch feed orifice throughout the 3-4 upshift. Instead, once a predetermined pressure develops within the clutch, the valve closes the bypass. Clutch fill is then completed through the regular feed orifice. THROTTLE VALVE Throttle Valve In all gear positions, the throttle valve is being supplied with line pressure. The throttle valve meters and reduces the line pressure that now becomes throttle pressure. The throttle valve is moved by a spring and the kickdown valve, which is mechanically connected to the throttle. The larger the throttle opening, the higher the throttle pressure (to a maximum of line pressure). The smaller the throttle opening, the lower the throttle pressure (to a minimum of zero at idle). As engine speed increases, the increase in pump speed increases pump output. The increase in pressure and volume must be regulated to maintain the balance within the transmission. To do this, throttle pressure is routed to the reaction area on the right side of the throttle pressure plug (in the regulator valve). The higher engine speed and line pressure would open the vent too far and reduce line pressure too much. Throttle pressure, which increases with engine speed (throttle opening), is used to oppose the movement of the pressure valve to help control the metering passage at the vent. The throttle pressure is combined with spring pressure to reduce the force of the throttle pressure plug on the pressure valve. The larger spring at the right closes the regulator valve passage and maintains or increases line pressure. The increased line pressure works against the reaction area of the line pressure plug and the Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8878 reaction area left of land #3 simultaneously moves the regulator valve train to the right and controls the metering passage. The kickdown valve, along with the throttle valve, serve to delay upshifts until the correct vehicle speed has been reached. It also controls downshifts upon driver demand, or increased engine load. If these valves were not in place, the shift points would be at the same speed for all throttle positions. The kickdown valve is actuated by a cam connected to the throttle. This is accomplished through either a linkage or a cable. The cam forces the kickdown valve toward the throttle valve compressing the spring between them and moving the throttle valve. As the throttle valve land starts to uncover its port, line pressure is "metered" out into the circuits and viewed as throttle pressure. This increased throttle pressure is metered out into the circuits it is applied to: the 1-2 and 2-3 shift valves. When the throttle pressure is high enough, a 3-2 downshift will occur. If the vehicle speed is low enough, a 2-1 downshift will occur. SWITCH VALVE Switch Valve - Torque Converter Unlocked When the transmission is in Drive Second before the TCC application occurs, the pressure regulator valve is supplying torque converter pressure to the switch valve. The switch valve directs this pressure through the transmission input shaft, into the converter, through the converter, back out between the input shaft and the reaction shaft, and back up to the switch valve. From the switch valve, the fluid pressure is directed to the transmission cooler, and lubrication pressure returns from the cooler to lubricate different portions of the transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8879 Switch Valve - Torque Converter Locked MANUAL VALVE The manual valve is a relay valve. The purpose of the manual valve is to direct fluid to the correct circuit needed for a specific gear or driving range. The manual valve, as the name implies, is manually operated by the driver with a lever located on the side of the valve body. The valve is connected mechanically by either a cable or linkage to the gearshift mechanism. The valve is held in each of its positions by a spring-loaded roller or ball that engages the "roostercomb" of the manual valve lever. Manual Valve Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8880 Once the TCC control valve has moved to the right, line pressure is directed to the tip of the switch valve, forcing the valve to the right. The switch valve now vents oil from the front of the piston in the torque converter, and supplies line pressure to the (rear) apply side of the torque converter piston. This pressure differential causes the piston to apply against the friction material, cutting off any further flow of line pressure oil. After the switch valve is shuttled right allowing line pressure to engage the TCC, torque converter pressure is directed past the switch valve into the transmission cooler and lubrication circuits. CONVERTER CLUTCH LOCK-UP VALVE The torque converter clutch (TCC) lock-up valve controls the back (ON) side of the torque converter clutch. When the PCM energizes the TCC solenoid to engage the converter clutch piston, pressure is applied to the TCC lock-up valve which moves to the right and applies pressure to the torque converter clutch. CONVERTER CLUTCH LOCK-UP TIMING VALVE The torque converter clutch (TCC) lock-up timing valve is there to block any 4-3 downshift until the TCC is completely unlocked and the clutch is disengaged. SHUTTLE VALVE The assembly is contained in a bore in the valve body above the shift valves. When the manual valve is positioned in the Drive range, throttle pressure acts on the throttle plug of the shuttle valve to move it against a spring, increasing the spring force on the shuttle valve. During a part or full throttle 1-2 upshift, the throttle plug is bottomed by throttle pressure, holding the shuttle valve to the right against governor pressure, and opening a by-pass circuit. The shuttle valve controls the quality of the kickdown shift by restricting the rate of fluid discharge from the front clutch and servo release circuits. During a 3-2 kickdown, fluid discharges through the shuttle by-pass circuit. When the shuttle valve closes the by-pass circuit, fluid discharge is restricted and controlled for the application of the front band. During a 2-3 "lift foot" upshift, the shuttle valve by-passes the restriction to allow full fluid flow through the by-pass groove for a faster release of the band. BOOST VALVE Boost Valve Before Lock-up The boost valve provides increased fluid apply pressure to the overdrive clutch during 3-4 upshifts, and when accelerating in fourth gear. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8881 Boost Valve After Lock-up The boost valve also serves to increase line pressure during torque converter lock-up. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8882 Accumulator: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION Valve Body Components The valve body consists of a cast aluminum valve body, a separator plate, and a transfer plate. The valve body contains valves and check balls that control fluid delivery to the torque converter clutch and frictional clutches. The valve body contains the following components: - Solenoid switch valve - Manual valve - Low/reverse shuttle valve - 5 Accumulators Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8883 Check Ball Locations - 7 check balls Operation OPERATION NOTE: Refer to the Hydraulic Schematics for a visual aid in determining valve location, operation and design. SOLENOID SWITCH VALVE The Solenoid Switch Valve (SSV) controls the direction of the transmission fluid when the L/R-TCC solenoid is energized. The Solenoid Switch Valve controls line pressure from the LR-TCC solenoid. In 1st gear, the SSV will be in the downshifted position, thus directing fluid to the L/R clutch circuit. In all other gears, the solenoid switch valve will be in the upshifted position and directs the fluid into the torque converter clutch (TCC) circuit. When shifting into 1st gear, a special hydraulic sequence is performed to ensure SSV movement into the downshifted position. The L/R pressure switch is monitored to confirm SSV movement. If the movement is not confirmed (the L/R pressure switch does not close), 2nd gear is substituted for 1st. A DTC will be set after three unsuccessful attempts are made to get into 1st gear in one given key start. MANUAL VALVE The manual valve is a relay valve. The purpose of the manual valve is to direct fluid to the correct circuit needed for a specific gear or driving range. The manual valve, as the name implies, is manually operated by the driver with a lever located on the top of the valve body. The valve is connected mechanically to the gearshift mechanism. The valve is held in each of its positions by a roller detent spring (2) that engages the roostercomb of the TRS selector plate (1). LOW/REVERSE SWITCH VALVE The low/reverse switch valve allows the low/reverse clutch to be operated by either the LR/CC solenoid or the MS solenoid. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8884 Accumulator: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION The valve body consists of a two piece aluminum valve body. Extensive electronic control effected by a microcomputer (the automatic transmission electronic control unit) over the hydraulic circuitry enables precise control over gearshifts. The valve body contains valves and pressure sensors that control fluid delivery to the torque converter clutch, forward clutches, and brake clutches. UPPER VALVE BODY UPPER VALVE BODY The upper valve body contains the following components: - 1 = Combined Drain - 2 = Gain change solenoid valve - 3 = Manual valve - 4 = Modulator valve - 5 = Shift solenoid valve No. 3 - 6 = Shift solenoid valve No. 2 - 7 = Shift valve No. 1 LOWER VALVE BODY Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8885 LOWER VALVE BODY The lower valve body contains the following components: - 1 = Control valve No. 3 - 2 = Shift solenoid valve No. 4 - 3 = Lockup control valve - 4 = Control valve No. 1 - 5 = Control valve No. 2 SWITCHES AND SOLENOIDS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8886 VALVE BODY OIL SWITCH HARNESS There are eight pressure switches and one ATF temperature switch used to inform the Transmission Control Module (TCM) when there is pressure in various hydraulic circuits. Six of them are located on the bottom of the valve body. The remainder are located on the top of the valve body. SWITCHES AND SOLENOIDS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8887 VALVE BODY SOLENOID HARNESS Eight solenoids are used to control various shift functions in the transmission. Four are located on the top of the valve body (3, 4) and the remainder are located on the bottom of the valve body. Operation OPERATION LOWER VALVE BODY Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8888 LOWER VALVE BODY UPPER VALVE BODY Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8889 UPPER VALVE BODY Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8890 SWITCHES AND SOLENOIDS VALVE BODY OIL SWITCH HARNESS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8891 SWITCHES AND SOLENOIDS VALVE BODY SOLENOID HARNESS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8892 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set Control Module: Customer Interest Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 8901 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 8902 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: Customer Interest A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 8907 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 8908 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set Control Module: Customer Interest A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8913 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8914 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8915 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8916 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set Control Module: All Technical Service Bulletins Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 8922 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 8923 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: All Technical Service Bulletins A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 8928 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 8929 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set Control Module: All Technical Service Bulletins A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8934 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8935 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8936 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 8937 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8938 Control Module: Locations Component ID: 214 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2-3 POWER TAKEOFF RELAY ENABLE K427 18OR/LG 4-5 PRESSURE SIGNAL 4 T803 20DG/BR 6 PRESSURE SIGNAL 1 T800 20DG/BR 7-8-9-10 - 11 PRESSURE SIGNAL 5 T804 20YL/DB 12 PRESSURE SIGNAL 3 T802 20DG/PK 13 - 14 - 15 - 16 PRESSURE SIGNAL 6 T805 20DG/OR 17 PRESSURE SIGNAL 2 T801 20DG/RD Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8939 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Description Circuit 1 8 VOLT SUPPLY T72 20YL/DB 2 OUTPUT SPEED SIGNAL T14 20DG/BR 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8940 5-6-7 FUSED B(+) A104 20YL/RD 8 GROUND Z133 18BK/LG 9-10 - 11 - 12 - 13 - 14 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 15 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 16 TCC TEMPERATURE SIGNAL T819 20YL/VT 17 GROUND Z133 18BK/LG 18 - 19 SHIFT 4 CONTROL T811 20DG/LB 20 CAN C BUS (+) D65 20WT/LG 21 CAN C BUS (-) D64 20WT/LB 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8941 Pin Description Circuit 1 SHIFT 1 CONTROL T808 20DG/GY 2-3 SHIFT 3 CONTROL T810 20DG/DB 4-5 LINEAR 3 CONTROL T817 20YL/BR 6 LINEAR 1 GROUND T812 20DG/TN 7 LINEAR 1 CONTROL T813 20DG/LG 8 LINEAR 2 CONTROL T815 20YL/RD 9 LINEAR 2 GROUND T814 20YL/BR 10 PRESSURE SIGNAL 7 T806 20DG/VT 11 - 12 - 13 - 14 - - 15 LINEAR 3 GROUND T816 20YL/PK 16 TRS 1 SIGNAL T828 20DG/DB 17 TRS T42 SIGNAL T42 20DG/YL 18 TRS T3 SIGNAL T3 20DG/DB 19 TRS DRIVE SIGNAL T827 20DG/LB 20 TRS PARK SIGNAL T824 20YL/DB 21 TRS REVERSE SIGNAL T826 20DG/DB 22 SHIFT 2 CONTROL T809 20DG/YL 23 - 24 - 25 - 26 PRESSURE SIGNAL 8 T807 20DG/WT 27 - 28 TEMPERATURE SENSOR GROUND T820 20YL/WT 29 TRS NEUTRAL SIGNAL T825 20DG/YL 30 LINEAR 4 CONTROL T821 20YL/GY 31 LINEAR 4 GROUND T818 20YL/OR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8942 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8943 Control Module: Diagrams Component ID: 214 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2-3 POWER TAKEOFF RELAY ENABLE K427 18OR/LG 4-5 PRESSURE SIGNAL 4 T803 20DG/BR 6 PRESSURE SIGNAL 1 T800 20DG/BR 7-8-9-10 - 11 PRESSURE SIGNAL 5 T804 20YL/DB 12 PRESSURE SIGNAL 3 T802 20DG/PK 13 - 14 - 15 - 16 PRESSURE SIGNAL 6 T805 20DG/OR 17 PRESSURE SIGNAL 2 T801 20DG/RD Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8944 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Description Circuit 1 8 VOLT SUPPLY T72 20YL/DB 2 OUTPUT SPEED SIGNAL T14 20DG/BR 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8945 5-6-7 FUSED B(+) A104 20YL/RD 8 GROUND Z133 18BK/LG 9-10 - 11 - 12 - 13 - 14 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 15 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 16 TCC TEMPERATURE SIGNAL T819 20YL/VT 17 GROUND Z133 18BK/LG 18 - 19 SHIFT 4 CONTROL T811 20DG/LB 20 CAN C BUS (+) D65 20WT/LG 21 CAN C BUS (-) D64 20WT/LB 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8946 Pin Description Circuit 1 SHIFT 1 CONTROL T808 20DG/GY 2-3 SHIFT 3 CONTROL T810 20DG/DB 4-5 LINEAR 3 CONTROL T817 20YL/BR 6 LINEAR 1 GROUND T812 20DG/TN 7 LINEAR 1 CONTROL T813 20DG/LG 8 LINEAR 2 CONTROL T815 20YL/RD 9 LINEAR 2 GROUND T814 20YL/BR 10 PRESSURE SIGNAL 7 T806 20DG/VT 11 - 12 - 13 - 14 - - 15 LINEAR 3 GROUND T816 20YL/PK 16 TRS 1 SIGNAL T828 20DG/DB 17 TRS T42 SIGNAL T42 20DG/YL 18 TRS T3 SIGNAL T3 20DG/DB 19 TRS DRIVE SIGNAL T827 20DG/LB 20 TRS PARK SIGNAL T824 20YL/DB 21 TRS REVERSE SIGNAL T826 20DG/DB 22 SHIFT 2 CONTROL T809 20DG/YL 23 - 24 - 25 - 26 PRESSURE SIGNAL 8 T807 20DG/WT 27 - 28 TEMPERATURE SENSOR GROUND T820 20YL/WT 29 TRS NEUTRAL SIGNAL T825 20DG/YL 30 LINEAR 4 CONTROL T821 20YL/GY 31 LINEAR 4 GROUND T818 20YL/OR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8947 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Description Control Module: Description and Operation Description DESCRIPTION On gasoline vehicles the Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). 68RFE TCM LOCATION Vehicles equipped 68RFE transmission and a 6.7L Diesel engine, the TCM is housed in the NGC4 controller utilizing only the C1 and C4 connectors (TCM only). The controller is located at the rear of the engine compartment, near the right inner fender. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Description > Page 8950 AS68RC TCM LOCATION On Cab Chassis models equipped with the AS68RC transmission the Transmission Control Module (TCM) has three electrical connectors and is located in the passenger compartment underneath of the left side of the dash panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Description > Page 8951 Control Module: Description and Operation Operation OPERATION RLE and RFE TRANSMISSIONS The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) (if equipped) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Description > Page 8952 An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Description > Page 8953 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Description > Page 8954 SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Description > Page 8955 AISIN AS68RC TRANSMISSION The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Speed Sensor - Output Speed Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Description > Page 8956 - Manifold Pressure - Throttle position - Torque Reduction Confirmation - Engine Coolant Temperature - Exhaust Brake Status (if equipped) - PTO Request (if equipped) - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Exhaust Brake Cut Request (if equipped). - Solenoids. - Torque Reduction Request. Some examples of TCM .indirect outputs are: - Transmission Temperature (to PCM). - PRNDL Position (to cluster/CCN). - PTO Status. In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI). - Storing and selecting appropriate Shift Schedules. - System self-diagnostics. - Diagnostic capabilities (with scan tool). Clutch filling time is continuously maintained when the vehicle is running. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 8962 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 8967 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 8968 Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 8969 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 8970 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 8971 Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 8972 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 8973 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Service Fill 42RLE .................................................................................................................................................. ...................................................... 3.8Liters (4.0 Qt) 45RFE/545RFE 4X2 ............................................................................................................................ ................................................................................. 5.2Liters (5.5 Qt) 4X4 ........................................ .............................................................................................................................................................. ....... 6.2Liters (6.5 Qt) 48RE .................................................................................................................................................... ....................................................... 3.8Liters (4.0 Qt) 68RFE 4X2 .......................................................................................................................................... ................................................................... 5.2Liters (5.5 Qt) 4X4 ...................................................... ....................................................................................................................................................... 6.2Liters (6.5 Qt) AS68RC ............................................................................................................................................... ...................................................... 6.8Liters (7.2 Qt) Overhaul * 42RLE .................................................................................................................................................. ...................................................... 8.3Liters (8.7 Qt) 45RFE/545RFE ................................................................................................................................... ........................................ 14-16Liters (14.8-16.9 Qt) 48RE .................................................................................................................................................... ........................................ 14-16Liters (14.8-16.9 Qt) 68RFE ................................................................................................................................................. ................................... 15.6-16.6Liters (16.4-17.5 Qt) AS68RC ............................................................................................................................................... ................................................ 13.0Liters (13.74 Qt) *Dry fill capacity. Depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler, these figures may vary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 8976 Fluid - A/T: Fluid Type Specifications AUTOMATIC TRANSMISSION FLUID (All but AISIN Transmission) Mopar ATF +4 Automatic Transmission Fluid AISIN TRANSMISSION Mopar AS68RC Automatic Transmission Fluid Dexron II fluid IS NOT recommended. Clutch chatter can result from the use of improper fluid. NOTE: Mopar ATF +4 and AS68RC, Automatic Transmission Fluids when new are red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF +4 and AS68RC, also have a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. DaimlerChrysler strongly recommends against the addition of any fluids to the transmission, other than those automatic transmission fluids listed above. Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks. Various "special" additives and supplements exist that claim to improve shift feel and/or quality. These additives and others also claim to improve converter clutch operation and inhibit overheating, oxidation, varnish and sludge. These claims have not been supported to the satisfaction of DaimlerChrysler and these additives must not be used. The use of transmission "sealers" should also be avoided, since they may adversely affect the integrity of transmission seals. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > 68RFE Automatic Transmission Fluid - A/T: Testing and Inspection 68RFE Automatic Transmission Effects Of Incorrect Fluid Level EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Causes Of Burnt Fluid CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. 1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. 2. A result of restricted fluid flow through the main and auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged oil cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Fluid Contamination FLUID CONTAMINATION Transmission fluid contamination is generally a result of: - adding incorrect fluid - failure to clean dipstick and fill tube when checking level - engine coolant entering the fluid - internal failure that generates debris - overheat that generates sludge (fluid breakdown) - failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > 68RFE Automatic Transmission > Page 8979 Fluid - A/T: Testing and Inspection 48RE Automatic Transmission Effects Of Incorrect Fluid Level EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Causes Of Burnt Fluid CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has two primary causes. 1. A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged oil cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 2. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Fluid Contamination FLUID CONTAMINATION Transmission fluid contamination is generally a result of: - adding incorrect fluid - failure to clean dipstick and fill tube when checking level - engine coolant entering the fluid - internal failure that generates debris - overheat that generates sludge (fluid breakdown) - failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > 68RFE Automatic Transmission > Page 8980 Fluid - A/T: Testing and Inspection AS68RC Automatic Transmission Effects Of Incorrect Fluid Level EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Causes Of Burnt Fluid CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. 1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. 2. A result of restricted fluid flow through the main and/or auxiliary cooler. 3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Fluid Contamination FLUID CONTAMINATION Transmission fluid contamination is generally a result of: - adding incorrect fluid. - failure to clean dipstick and fill tube when checking level. - engine coolant entering the fluid. - internal failure that generates debris. - overheat that generates sludge (fluid breakdown). - failure to replace contaminated converter after repair. The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The torque converter should be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Fluid - A/T: Service and Repair 68RFE Automatic Transmission Fluid Level Check FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmssion has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P (PARK) and N (NEUTRAL) positions. Place the selector lever in P (PARK) to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82° C. or 180° F), the fluid level is correct if it is in the HOT region (cross-hatched area) on the oil level indicator. The fluid level will be approximately at the upper COLD hole of the dipstick at 21° C (70° F) fluid temperature. FILL TUBE EQUIPPED WITH INDICATOR NOTE: Engine and Transmission should be at normal operating temperature before performing this procedure. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Hook up scan tool and select transmission. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the Transmission Fluid Temperature Chart. NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8983 transmission before rechecking the fluid level. 10. Check transmission for leaks. CAPPED FILL TUBE 1. Verify that the vehicle is parked on a level surface. 2. Remove the dipstick tube cap. WARNING: There is a risk of accident from vehicle starting off by itself when engine is running. There is a risk of injury from contusions and burns if you insert your hands into the engine when it is started or when it is running. Secure vehicle to prevent it from moving off by itself. Wear properly fastened and close-fitting work clothes. Do not touch hot or rotating parts. 3. Actuate the service brake. Start engine and let it run at idle speed in selector lever position "P". 4. Shift through the transmission modes several times with the vehicle stationary and the engine idling. 5. Warm up the transmission, wait at least 2 minutes and check the oil level with the engine running. Push the Oil Dipstick 9336 into transmission fill tube until the dipstick tip contacts the oil pan and pull out again, read off oil level, repeat if necessary. NOTE: The dipstick will protrude from the fill tube when installed. 6. Check transmission oil temperature using the appropriate scan tool. NOTE: The true transmission oil temperature can only be read by a scan tool in REVERSE or any forward gear position. 7. The transmission Oil Dipstick 9336 has indicator marks every 10 mm. Determine the height of the oil level on the dipstick and using the height, the transmission temperature, and the Transmission Fluid Graph, determine if the transmission oil level is correct. 8. Add or remove oil as necessary and recheck the oil level. 9. Once the oil level is correct, install the dipstick tube cap. Fluid And Filter Replacement FLUID AND FILTER REPLACEMENT REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8984 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. Transmission Filters - 4X4 Shown 9. Remove the screw holding the primary oil filter (1) to valve body. 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Inspect the oil filter seal in the bottom of the oil pump. If the seal is not installed completely in the oil pump, or is otherwise damaged, then remove and discard the oil filter seal from the bottom of the oil pump. If the seal is installed correctly and is in good condition, it can be reused. 12. If replacing the cooler return filter (2), use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the diagnosis information. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8985 Transmission Filters - 4X4 Shown CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 1. If necessary, install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with Installer 6960-A or another suitable tool (appropriately sized drift or socket, the butt end of a hammer etc.). 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold the primary oil filter (1) to valve body. Tighten screw to 4.5 Nm (40 in. lbs.) torque. 4. Install new cooler return filter (2) onto the transmission, if necessary. Torque the filter to 9.5 Nm (84 in.lbs.). 5. Place bead of Mopar(R) RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 12 Nm (105 in. lbs.) torque. 8. Lower vehicle and fill transmission with MOPAR(R) ATF +4. Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar(R) ATF +4 to transmission: a. If only fluid and filter were changed, add 10 pints (5 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled and the torque converter was replaced or drained, add 24 pints (12 quarts) of ATF +4 to transmission. 3. Check the transmission fluid, refer to FLUID - STANDARD PROCEDURE and adjust as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8986 Fluid - A/T: Service and Repair 48RE Automatic Transmission Fluid Level Check FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmssion has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. The transmission fluid level can be checked two ways. PROCEDURE ONE 1. Transmission fluid must be at normal operating temperature for accurate fluid level check. Drive vehicle if necessary to bring fluid temperature up to normal hot operating temperature of 82°C (180°F). 2. Position vehicle on level surface. 3. Start and run engine at curb idle speed. 4. Apply parking brakes. 5. Shift transmission momentarily into all gear ranges. Then shift transmission back to NEUTRAL. 6. Clean top of filler tube and dipstick to keep dirt from entering tube. 7. Remove dipstick (1) and check fluid level as follows: a. Correct acceptable level is in crosshatch area. b. Correct maximum level is to MAX arrow mark. c. Incorrect level is at or below MIN line. d. If fluid is low, add only enough Mopar(R) ATF +4 to restore correct level. Do not overfill. PROCEDURE TWO Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8987 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into NEUTRAL. 5. Hook up scan tool and select engine. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the chart. NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Fluid And Filter Replacement FLUID AND FILTER REPLACEMENT The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan (3). 3. Remove bolts holding front and sides of pan to transmission (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8988 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan and reusable gasket (2) away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolt holding pan to transmission. 7. While holding pan level, lower pan and gasket away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screws holding filter (2) to valve body. 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used trans fluid and filter properly. INSTALLATION 1. Position a new transmission oil filter (2) onto the valve body. 2. Install the screws to hold the filter to the valve body. Tighten the screws to 4 Nm (35 in.lbs.). 3. Clean the gasket surfaces of the transmission oil pan (3) and transmission pan rail. NOTE: The transmission pan oil gasket (2) is reusable. Inspect the sealing surfaces of the gasket. If the sealing ribs on both surfaces Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8989 appear to be in good condition, clean the gasket of any foreign material and reinstall. 4. Position the oil pan gasket (2) onto the oil pan (3). 5. Position the oil pan and gasket onto the transmission and install several bolts to hold the pan and gasket to the transmission. 6. Install the remainder of the oil pan bolts. Tighten the bolts to 13.6 Nm (125 in.lbs.). 7. Lower vehicle and fill transmission. Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar(R) ATF +4 to transmission: a. If only fluid and filter were changed, add 3 pints (1-1/2 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, torque converter was replaced or drained, and cooler was flushed, add 12 pints (6 quarts) of ATF +4 to transmission. 3. Apply parking brakes. 4. Start and run engine at normal curb idle speed. 5. Apply service brakes, shift transmission through all gear ranges then back to NEUTRAL, set parking brake, and leave engine running at curb idle speed. 6. Remove funnel, insert dipstick and check fluid level. If level is low, add fluid to bring level to MIN mark on dipstick. Check to see if the oil level is equal on both sides of the dipstick. If one side is noticeably higher than the other, the dipstick has picked up some oil from the dipstick tube. Allow the oil to drain down the dipstick tube and re-check. 7. Drive vehicle until transmission fluid is at normal operating temperature. 8. With the engine running at curb idle speed, the gear selector in NEUTRAL, and the parking brake applied, check the transmission fluid level. CAUTION: Do not overfill transmission, fluid foaming and shifting problems can result. 9. Add fluid to bring level up to MAX arrow mark. When fluid level is correct, shut engine off, release park brake, remove funnel, and install dipstick in fill tube. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8990 Fluid - A/T: Service and Repair AS68RC Automatic Transmission Fluid Level Check FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmission has too much fluid, the gear train churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P (PARK) and N (NEUTRAL) positions. Place the selector lever in P (PARK) to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82° C. or 180° F), the fluid level is correct if it is in the HOT region (cross-hatched area) on the oil level indicator. The fluid level will be approximately at the upper COLD hole of the dipstick at 21° C (70° F) fluid temperature. NOTE: Engine and Transmission should be at normal operating temperature before performing this procedure. Optimum fluid temperature for checking the level should be between 70°C (158°F) and 80°C ( 176°F). 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Connect the scan tool and select transmission. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the Transmission Fluid Temperature Chart. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8991 NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Fluid And Filter Replacement FLUID AND FILTER REPLACEMENT REMOVAL DRAIN PLUG 1. Raise vehicle. 2. Place a large diameter drain pan beneath the transmission pan. 3. Remove the drain plug bolt (1) and allow the oil to drain from the transmission pan. 4. Remove the drain pan bolts from the transmission case. 5. Remove the drain pan. TRANSMISSION OIL FILTER Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8992 6. Remove the transmission oil filter bolts (3). 7. Remove the transmission oil filter and O-ring seal from the valve body (1). INSPECTION OIL PAN MAGNETS Inspect bottom of pan, pick-up magnets (1) and magnetic drain plug (2) and fluid filter for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the diagnosis information. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8993 TRANSMISSION OIL FILTER 1. Lubricate the transmission oil filter seal with MOPAR(R) AS68RC ATF. 2. Install the new transmission oil filter (2) in position on valve body (1) and into the oil pump. 3. Install the transmission oil filter bolts (3). 4. Tighten bolts to 10 Nm ( 88 in.lbs. ) torque. 5. Install a new transmission oil pan gasket. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 7 Nm (62 in. lbs.) torque. DRAIN PLUG 8. Install transmission drain plug bolt (1). 9. Tighten oil pan drain plug to 27 Nm ( 20 ft.lbs) torque. 10. Lower vehicle and fill transmission with MOPAR(R) AS68RC ATF. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8994 Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar(R) AS68RC ATF to transmission: a. If only fluid and filter were changed, add 6.8L (7.2 quarts) of AS68RC to transmission. b. If transmission was completely overhauled and the torque converter was replaced or drained, add 13L (13.75 quarts) of Mopar(R) AS68RC ATF to transmission. 3. Check the transmission fluid and adjust as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Fluid Filter - A/T: Service and Repair 68RFE Automatic Transmission FLUID AND FILTER REPLACEMENT REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. Transmission Filters - 4X4 Shown 9. Remove the screw holding the primary oil filter (1) to valve body. 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Inspect the oil filter seal in the bottom of the oil pump. If the seal is not installed completely in the oil pump, or is otherwise damaged, then remove and discard the oil filter seal from the bottom of the oil pump. If the seal is installed correctly and is in good condition, it can be reused. 12. If replacing the cooler return filter (2), use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the diagnosis information. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8999 Transmission Filters - 4X4 Shown CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 1. If necessary, install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with Installer 6960-A or another suitable tool (appropriately sized drift or socket, the butt end of a hammer etc.). 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold the primary oil filter (1) to valve body. Tighten screw to 4.5 Nm (40 in. lbs.) torque. 4. Install new cooler return filter (2) onto the transmission, if necessary. Torque the filter to 9.5 Nm (84 in.lbs.). 5. Place bead of Mopar(R) RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 12 Nm (105 in. lbs.) torque. 8. Lower vehicle and fill transmission with MOPAR(R) ATF +4. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9000 Fluid Filter - A/T: Service and Repair 48RE Automatic Transmission FLUID AND FILTER REPLACEMENT The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan (3). 3. Remove bolts holding front and sides of pan to transmission (1). 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan and reusable gasket (2) away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolt holding pan to transmission. 7. While holding pan level, lower pan and gasket away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screws holding filter (2) to valve body. 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used trans fluid and filter properly. INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9001 1. Position a new transmission oil filter (2) onto the valve body. 2. Install the screws to hold the filter to the valve body. Tighten the screws to 4 Nm (35 in.lbs.). 3. Clean the gasket surfaces of the transmission oil pan (3) and transmission pan rail. NOTE: The transmission pan oil gasket (2) is reusable. Inspect the sealing surfaces of the gasket. If the sealing ribs on both surfaces appear to be in good condition, clean the gasket of any foreign material and reinstall. 4. Position the oil pan gasket (2) onto the oil pan (3). 5. Position the oil pan and gasket onto the transmission and install several bolts to hold the pan and gasket to the transmission. 6. Install the remainder of the oil pan bolts. Tighten the bolts to 13.6 Nm (125 in.lbs.). 7. Lower vehicle and fill transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9002 Fluid Filter - A/T: Service and Repair AS68RC Automatic Transmission FLUID AND FILTER REPLACEMENT REMOVAL DRAIN PLUG 1. Raise vehicle. 2. Place a large diameter drain pan beneath the transmission pan. 3. Remove the drain plug bolt (1) and allow the oil to drain from the transmission pan. 4. Remove the drain pan bolts from the transmission case. 5. Remove the drain pan. TRANSMISSION OIL FILTER Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9003 6. Remove the transmission oil filter bolts (3). 7. Remove the transmission oil filter and O-ring seal from the valve body (1). INSPECTION OIL PAN MAGNETS Inspect bottom of pan, pick-up magnets (1) and magnetic drain plug (2) and fluid filter for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the diagnosis information. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9004 TRANSMISSION OIL FILTER 1. Lubricate the transmission oil filter seal with MOPAR(R) AS68RC ATF. 2. Install the new transmission oil filter (2) in position on valve body (1) and into the oil pump. 3. Install the transmission oil filter bolts (3). 4. Tighten bolts to 10 Nm ( 88 in.lbs. ) torque. 5. Install a new transmission oil pan gasket. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 7 Nm (62 in. lbs.) torque. DRAIN PLUG 8. Install transmission drain plug bolt (1). 9. Tighten oil pan drain plug to 27 Nm ( 20 ft.lbs) torque. 10. Lower vehicle and fill transmission with MOPAR(R) AS68RC ATF. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 68RFE Automatic Transmission Fluid Pan: Specifications 68RFE Automatic Transmission Fluid Pan Tighten bolts to .................................................................................................................... ..................................................... 12 Nm (105 in. lbs.) torque. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 68RFE Automatic Transmission > Page 9009 Fluid Pan: Specifications 48RE Automatic Transmission Transmission oil pan NOTE: The transmission pan oil gasket (2) is reusable. Inspect the sealing surfaces of the gasket. If the sealing ribs on both surfaces appear to be in good condition, clean the gasket of any foreign material and reinstall. Tighten the bolts to .............................................................................................................................. ............................................... 13.6 Nm (125 in.lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 68RFE Automatic Transmission > Page 9010 Fluid Pan: Specifications AS68RC Automatic Transmission Fluid Pan Tighten bolts to .................................................................................................................... ......................................................... 7 Nm (62 in. lbs.) torque. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Component ID: 410 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Description Circuit 1 SENSOR GROUND T160 20DG/WT Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 5 VOLT SUPPLY F856 20YL/PK 3 LINE PRESSURE SIGNAL T38 20YL/BR 4-- Component Location - 23 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 9014 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 9015 Fluid Pressure Sensor/Switch: Diagrams Component ID: 410 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Description Circuit 1 SENSOR GROUND T160 20DG/WT Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 5 VOLT SUPPLY F856 20YL/PK 3 LINE PRESSURE SIGNAL T38 20YL/BR 4-- Component Location - 23 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 9016 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description Fluid Pressure Sensor/Switch: Description and Operation Description DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, which is part of the pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the pump inlet. The system contains a Line Pressure Sensor, which is a direct input to the TCM. The line pressure sensor monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description > Page 9019 Fluid Pressure Sensor/Switch: Description and Operation Operation OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts, to ensure consistent shift quality. During all other operation, the desired line pressure value is adjusted based on torque level and other transmission requirements. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal Fluid Pressure Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal > Page 9022 Fluid Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Testing and Inspection > 68RFE Automatic Transmission Fluid Pump: Testing and Inspection 68RFE Automatic Transmission STANDARD PROCEDURE - OIL PUMP VOLUME CHECK Measuring the oil pump output volume will determine if sufficient oil flow to the transmission oil cooler exists, and whether or not an internal transmission failure is present. Verify that the transmission fluid is at the proper level. Refer to the Fluid Level Check procedure. If necessary, fill the transmission to the proper level with Mopar(R) ATF +4, Automatic Transmission Fluid. 1. Disconnect the To cooler line at the cooler inlet and place a collecting container under the disconnected line. 2. Plug the inlet to the oil cooler. CAUTION: With the fluid set at the proper level, fluid collection should not exceed (1) quart or internal damage to the transmission may occur. 3. Run the engine at 1800 rpm, with the shift selector in neutral. Verify that the transmission fluid temperature is below 104.5° C (220° F) for this test. 4. If one quart of transmission fluid is collected in the container in 30 seconds or less, oil pump flow volume is within acceptable limits. If fluid flow is intermittent, or it takes more than 30 seconds to collect one quart of fluid, refer to the Hydraulic Pressure tests for further diagnosis. See: Testing and Inspection/Component Tests and General Diagnostics/68RFE Automatic Transmission/Hydraulic Pressure Test 5. Unplug the oil cooler inlet. 6. Re-connect the To cooler line to the transmission cooler inlet. 7. Refill the transmission to proper level. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Testing and Inspection > 68RFE Automatic Transmission > Page 9027 Fluid Pump: Testing and Inspection AS68RC Automatic Transmission OIL PUMP VOLUME CHECK Measuring the oil pump output volume will determine if sufficient oil flow to the transmission oil cooler exists, and whether or not an internal transmission failure is present. Verify that the transmission fluid is at the proper level. Refer to the Fluid Level Check procedure. If necessary, fill the transmission to the proper level with Mopar(R) AS68RC, Automatic Transmission Fluid. 1. Disconnect the To cooler line at the cooler inlet and place a collecting container under the disconnected line. CAUTION: With the fluid set at the proper level, fluid collection should not exceed one (1) quart or internal damage to the transmission may occur. 2. Run the engine at 1800 rpm, with the shift selector in neutral. Verify that the transmission fluid temperature is below 104.5° C (220° F) for this test. 3. If one quart of transmission fluid is collected in the container in 30 seconds or less, oil pump flow volume is within acceptable limits. If fluid flow is intermittent, or it takes more than 30 seconds to collect one quart of fluid, refer to the Hydraulic Pressure tests for further diagnosis. See: Testing and Inspection/Component Tests and General Diagnostics/AS68RC Automatic Transmission/Hydraulic Pressure Test 4. Install the To cooler line to the transmission cooler inlet. 5. Refill the transmission to proper level. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Description and Operation > Description Governor: Description and Operation Description DESCRIPTION Governor pressure is controlled electronically. Components used for governor pressure control include: - Governor body - Valve body transfer plate - Governor pressure solenoid valve - Governor pressure sensor - Fluid temperature thermistor - Throttle position sensor (TPS) - Transmission speed sensor - Powertrain control module (PCM) GOVERNOR PRESSURE SOLENOID VALVE The solenoid valve (2) is a duty-cycle solenoid which regulates the governor pressure needed for upshifts and downshifts. It is an electro-hydraulic device located in the governor body on the valve body transfer plate. GOVERNOR BODY, TRANSFER PLATE, AND PRESSURE SENSOR The governor pressure sensor (2) measures output pressure of the governor pressure solenoid valve. The transfer plate is designed to supply transmission line pressure to the governor pressure solenoid valve and to return governor pressure. The governor pressure solenoid valve is mounted in the governor body (1). The body is bolted to the lower side of the transfer plate. GOVERNOR PRESSURE CURVES There are four governor pressure curves programmed into the transmission control module. The different curves allow the control module to adjust governor pressure for varying conditions. One curve is used for operation when fluid temperature is at, or below, -1°C (30°F). A second curve is used when fluid temperature is at, or above, 10°C (50°F) during normal city or highway driving. A third curve is used during wide-open throttle operation. The fourth curve is used when driving with the transfer case in low range. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Description and Operation > Description > Page 9032 Governor: Description and Operation Operation OPERATION Compensation is required for performance variations of two of the input devices. Though the slope of the transfer functions is tightly controlled, offset may vary due to various environmental factors or manufacturing tolerances. The pressure transducer is affected by barometric pressure as well as temperature. Calibration of the zero pressure offset is required to compensate for shifting output due to these factors. Normal calibration will be performed when sump temperature is above 50 degrees F, or in the absence of sump temperature data, after the first 10 minutes of vehicle operation. Calibration of the pressure transducer offset occurs each time the output shaft speed falls below 200 RPM. Calibration shall be repeated each 3 seconds the output shaft speed is below 200 RPM. A 0.5 second pulse of 95% duty cycle is applied to the governor pressure solenoid valve and the transducer output is read during this pulse. Averaging of the transducer signal is necessary to reject electrical noise. Under cold conditions (below 50 degrees F sump), the governor pressure solenoid valve response may be too slow to guarantee 0 psi during the 0.5 second calibration pulse. Calibration pulses are continued during this period, however the transducer output valves are discarded. Transducer offset must be read at key-on, under conditions which promote a stable reading. This value is retained and becomes the offset during the "cold" period of operation. GOVERNOR PRESSURE SOLENOID VALVE The inlet side of the solenoid valve is exposed to normal transmission line pressure. The outlet side of the valve leads to the valve body governor circuit. The solenoid valve regulates line pressure to produce governor pressure. The average current supplied to the solenoid controls governor pressure. One amp current produces zero kPa/psi governor pressure. Zero amps sets the maximum governor pressure. The powertrain control module (PCM) turns on the trans control relay which supplies electrical power to the solenoid valve. Operating voltage is 12 volts (DC). The PCM controls the ground side of the solenoid using the governor pressure solenoid control circuit. GOVERNOR PRESSURE SENSOR The sensor output signal provides the necessary feedback to the PCM. This feedback is needed to adequately control governor pressure. GOVERNOR BODY AND TRANSFER PLATE The transfer plate channels line pressure to the solenoid valve through the governor body. It also channels governor pressure from the solenoid valve to the governor circuit. It is the solenoid valve that develops the necessary governor pressure. GOVERNOR PRESSURE CURVES LOW TRANSMISSION FLUID TEMPERATURE When the transmission fluid is cold the conventional governor can delay shifts, resulting in higher than normal shift speeds and harsh shifts. The electronically controlled low temperature governor pressure curve is higher than normal to make the transmission shift at normal speeds and sooner. The PCM uses a temperature sensor in the transmission oil sump to determine when low temperature governor pressure is needed. NORMAL OPERATION Normal operation is refined through the increased computing power of the PCM and through access to data on engine operating conditions provided by the PCM that were not available with the previous stand-alone electronic module. This facilitated the development of a load adaptive shift strategy - the ability to alter the shift schedule in response to vehicle load condition. One manifestation of this capability is grade "hunting" prevention - the ability of the transmission logic to delay an upshift on a grade if the engine does not have sufficient power to maintain speed in the higher gear. The 3-2 downshift and the potential for hunting between gears occurs with a heavily loaded vehicle or on steep grades. When hunting occurs, it is very objectionable because shifts are frequent and accompanied by large changes in noise and acceleration. WIDE OPEN THROTTLE OPERATION In wide-open throttle (WOT) mode, adaptive memory in the PCM assures that up-shifts occur at the preprogrammed optimum speed. WOT operation is determined from the throttle position sensor, which is also a part of the emission control system. The initial setting for the WOT upshift is below the optimum engine speed. As WOT shifts are repeated, the PCM learns the time required to complete the shifts by comparing the engine speed when the shifts occur to the optimum speed. After each shift, the PCM adjusts the shift point until the optimum speed is reached. The PCM also considers vehicle loading, grade and engine performance changes due to high altitude in determining when to make WOT shifts. It does this by measuring vehicle and engine acceleration and then factoring in the shift time. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Description and Operation > Description > Page 9033 TRANSFER CASE LOW RANGE OPERATION On four-wheel drive vehicles operating in low range, the engine can accelerate to its peak more rapidly than in Normal range, resulting in delayed shifts and undesirable engine "flare." The low range governor pressure curve is also higher than normal to initiate upshifts sooner. The PCM compares electronic vehicle speed signal used by the speedometer to the transmission output shaft speed signal to determine when the transfer case is in low range. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Removal Governor: Service and Repair Removal REMOVAL 1. Hoist and support vehicle on safety stands. 2. Remove transmission fluid pan and filter. 3. Disengage wire connectors from pressure sensor (1) and solenoid (2). 4. Remove screws holding pressure solenoid retainer (1) to governor body (2). 5. Separate solenoid retainer from governor. 6. Pull solenoid (1) from governor body (3). 7. Pull pressure sensor from governor body. 8. Remove bolts holding governor body to valve body. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Removal > Page 9036 9. Separate governor body (1) from valve body. 10. Remove governor body gasket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Removal > Page 9037 Governor: Service and Repair Installation INSTALLATION Before installing the pressure sensor and solenoid in the governor body, replace O-ring seals, clean the gasket surfaces and replace gasket. 1. Place gasket (2) in position on back of governor body (1). 2. Place governor body in position on valve body. 3. Install bolts to hold governor body to valve body. 4. Lubricate O-ring on pressure sensor with transmission fluid. 5. Align pressure sensor to bore in governor body. 6. Push pressure sensor into governor body. 7. Lubricate O-ring (2), on pressure solenoid (1), with transmission fluid. 8. Align pressure solenoid (1) to bore in governor body (3). 9. Push solenoid into governor body. 10. Place solenoid retainer (1) in position on governor (2). 11. Install screws to hold pressure solenoid retainer to governor body. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Removal > Page 9038 12. Engage wire connectors into pressure sensor (1) and solenoid (2). 13. Install transmission fluid pan and (new) filter. 14. Lower vehicle and road test to verify repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator Overdrive Indicator Lamp: Description and Operation Overdrive Off Indicator Description DESCRIPTION An overdrive off indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The overdrive off indicator consists of a stencil-like cutout of the text O/D OFF in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the overdrive off indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The overdrive off indicator is serviced as a unit with the instrument cluster. Operation OPERATION The overdrive off indicator gives an indication to the vehicle operator when the overdrive-OFF position of the tow/haul switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The overdrive off indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the overdrive off indicator for the following reasons: - Overdrive Off Indicator Lamp-On Message - Each time the cluster receives an electronic overdrive off indicator lamp-ON message from the PCM indicating that the overdrive-OFF position of the tow/haul switch has been selected, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the overdrive off indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the overdrive off indicator or the instrument cluster circuitry that controls the indicator, refer to Instrument Cluster/Carrier Testing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 9044 For proper diagnosis of the transmission control system, the PCM, the EMIC, the CAN data bus or the electronic communication related to overdrive off indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 9045 Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator Description DESCRIPTION A tow/haul indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The tow/haul indicator consists of a stencil-like cutout of the text TOW/HAUL in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the tow/haul indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The tow/haul indicator is serviced as a unit with the instrument cluster. Operation OPERATION The tow/haul indicator gives an indication to the vehicle operator when the tow/haul function of the tow/haul switch has been selected, revising the shift schedule of the electronically controlled automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The tow/haul indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the tow/haul indicator for the following reasons: - Tow/Haul Indicator Lamp-On Message - Each time the cluster receives an electronic tow/haul indicator lamp-ON message from the PCM indicating that the tow/haul shift schedule has been selected, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the tow/haul indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the tow/haul indicator or the instrument cluster circuitry that controls the indicator refer to Instrument Cluster / Carrier testing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 9046 For proper diagnosis of the transmission control system, the PCM, the EMIC, the CAN data bus or the electronic communication related to tow/haul indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description Temperature Warning Indicator - A/T: Description and Operation Description DESCRIPTION A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The transmission over-temperature indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Transmission Temperature in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The transmission over-temperature indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description > Page 9051 Temperature Warning Indicator - A/T: Description and Operation Operation OPERATION The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received over the Controller Area Network (CAN) data bus from the Powertrain Control Module (PCM). The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Indicator Lamp-On Message - Each time the cluster receives an electronic trans over-temp indicator lamp-ON message from the PCM indicating that the transmission fluid temperature is 135° C (275° F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the indicator is cycled OFF and then ON again by the appropriate lamp-ON and lamp-OFF messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the transmission over-temperature indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the instrument cluster illuminates the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission or the transmission cooling system are being overloaded, or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED,refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transmission temperature sensor, the PCM, the EMIC, the CAN data bus or the electronic communication related to transmission over-temperature indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Description Overdrive Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Description > Page 9057 Overdrive Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > Removal Overdrive Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > Removal > Page 9060 Overdrive Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator Overdrive Indicator Lamp: Description and Operation Overdrive Off Indicator Description DESCRIPTION An overdrive off indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The overdrive off indicator consists of a stencil-like cutout of the text O/D OFF in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the overdrive off indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The overdrive off indicator is serviced as a unit with the instrument cluster. Operation OPERATION The overdrive off indicator gives an indication to the vehicle operator when the overdrive-OFF position of the tow/haul switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The overdrive off indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the overdrive off indicator for the following reasons: - Overdrive Off Indicator Lamp-On Message - Each time the cluster receives an electronic overdrive off indicator lamp-ON message from the PCM indicating that the overdrive-OFF position of the tow/haul switch has been selected, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the overdrive off indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the overdrive off indicator or the instrument cluster circuitry that controls the indicator, refer to Instrument Cluster/Carrier Testing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 9065 For proper diagnosis of the transmission control system, the PCM, the EMIC, the CAN data bus or the electronic communication related to overdrive off indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 9066 Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator Description DESCRIPTION A tow/haul indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The tow/haul indicator consists of a stencil-like cutout of the text TOW/HAUL in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the tow/haul indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The tow/haul indicator is serviced as a unit with the instrument cluster. Operation OPERATION The tow/haul indicator gives an indication to the vehicle operator when the tow/haul function of the tow/haul switch has been selected, revising the shift schedule of the electronically controlled automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The tow/haul indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the tow/haul indicator for the following reasons: - Tow/Haul Indicator Lamp-On Message - Each time the cluster receives an electronic tow/haul indicator lamp-ON message from the PCM indicating that the tow/haul shift schedule has been selected, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the tow/haul indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the tow/haul indicator or the instrument cluster circuitry that controls the indicator refer to Instrument Cluster / Carrier testing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 9067 For proper diagnosis of the transmission control system, the PCM, the EMIC, the CAN data bus or the electronic communication related to tow/haul indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations Overdrive Switch: Locations Component ID: 490 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Description Circuit 123 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 4 GROUND Z71 20LB/BK 5 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 6 SENSOR GROUND T160 20DG/WT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 9071 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 9072 Overdrive Switch: Diagrams Component ID: 490 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Description Circuit 123 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 4 GROUND Z71 20LB/BK 5 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 6 SENSOR GROUND T160 20DG/WT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 9073 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 9074 Overdrive Switch: Testing and Inspection DIAGNOSIS AND TESTING - OVERDRIVE ELECTRICAL CONTROLS The tow/haul overdrive off switch, valve body solenoid, case connectors and related wiring can all be tested with a 12 volt test lamp or a volt/ohmmeter. Check continuity of each component when diagnosis indicates this is necessary. Switch and solenoid continuity should be checked whenever the transmission fails to shift into fourth gear range. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Switch: Service and Repair 42RLE Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9077 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9078 Overdrive Switch: Service and Repair 545RFE Automatic Transmission Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9079 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9080 Overdrive Switch: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9081 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9082 Overdrive Switch: Service and Repair AS68RC Automatic Transmission Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9083 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid Pressure Regulating Solenoid: Locations Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 9088 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 9089 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 9090 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 9091 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 9092 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 9093 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 9094 Pressure Regulating Solenoid: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 9095 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid Pressure Regulating Solenoid: Diagrams Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 9098 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 9099 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 9100 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 9101 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 9102 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 9103 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 9104 Pressure Regulating Solenoid: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 9105 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Description Pressure Regulating Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Description > Page 9108 Pressure Regulating Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Removal Pressure Regulating Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Removal > Page 9111 Pressure Regulating Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set Control Module: Customer Interest Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 9121 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 9122 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: Customer Interest A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 9127 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 9128 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set Control Module: Customer Interest A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 9133 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 9134 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 9135 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 9136 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set Control Module: All Technical Service Bulletins Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 9142 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 9143 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: All Technical Service Bulletins A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 9148 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 9149 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set Control Module: All Technical Service Bulletins A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 9154 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 9155 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 9156 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 9157 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9158 Control Module: Locations Component ID: 214 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2-3 POWER TAKEOFF RELAY ENABLE K427 18OR/LG 4-5 PRESSURE SIGNAL 4 T803 20DG/BR 6 PRESSURE SIGNAL 1 T800 20DG/BR 7-8-9-10 - 11 PRESSURE SIGNAL 5 T804 20YL/DB 12 PRESSURE SIGNAL 3 T802 20DG/PK 13 - 14 - 15 - 16 PRESSURE SIGNAL 6 T805 20DG/OR 17 PRESSURE SIGNAL 2 T801 20DG/RD Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9159 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Description Circuit 1 8 VOLT SUPPLY T72 20YL/DB 2 OUTPUT SPEED SIGNAL T14 20DG/BR 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9160 5-6-7 FUSED B(+) A104 20YL/RD 8 GROUND Z133 18BK/LG 9-10 - 11 - 12 - 13 - 14 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 15 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 16 TCC TEMPERATURE SIGNAL T819 20YL/VT 17 GROUND Z133 18BK/LG 18 - 19 SHIFT 4 CONTROL T811 20DG/LB 20 CAN C BUS (+) D65 20WT/LG 21 CAN C BUS (-) D64 20WT/LB 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9161 Pin Description Circuit 1 SHIFT 1 CONTROL T808 20DG/GY 2-3 SHIFT 3 CONTROL T810 20DG/DB 4-5 LINEAR 3 CONTROL T817 20YL/BR 6 LINEAR 1 GROUND T812 20DG/TN 7 LINEAR 1 CONTROL T813 20DG/LG 8 LINEAR 2 CONTROL T815 20YL/RD 9 LINEAR 2 GROUND T814 20YL/BR 10 PRESSURE SIGNAL 7 T806 20DG/VT 11 - 12 - 13 - 14 - - 15 LINEAR 3 GROUND T816 20YL/PK 16 TRS 1 SIGNAL T828 20DG/DB 17 TRS T42 SIGNAL T42 20DG/YL 18 TRS T3 SIGNAL T3 20DG/DB 19 TRS DRIVE SIGNAL T827 20DG/LB 20 TRS PARK SIGNAL T824 20YL/DB 21 TRS REVERSE SIGNAL T826 20DG/DB 22 SHIFT 2 CONTROL T809 20DG/YL 23 - 24 - 25 - 26 PRESSURE SIGNAL 8 T807 20DG/WT 27 - 28 TEMPERATURE SENSOR GROUND T820 20YL/WT 29 TRS NEUTRAL SIGNAL T825 20DG/YL 30 LINEAR 4 CONTROL T821 20YL/GY 31 LINEAR 4 GROUND T818 20YL/OR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9162 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9163 Control Module: Diagrams Component ID: 214 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2-3 POWER TAKEOFF RELAY ENABLE K427 18OR/LG 4-5 PRESSURE SIGNAL 4 T803 20DG/BR 6 PRESSURE SIGNAL 1 T800 20DG/BR 7-8-9-10 - 11 PRESSURE SIGNAL 5 T804 20YL/DB 12 PRESSURE SIGNAL 3 T802 20DG/PK 13 - 14 - 15 - 16 PRESSURE SIGNAL 6 T805 20DG/OR 17 PRESSURE SIGNAL 2 T801 20DG/RD Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9164 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Description Circuit 1 8 VOLT SUPPLY T72 20YL/DB 2 OUTPUT SPEED SIGNAL T14 20DG/BR 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9165 5-6-7 FUSED B(+) A104 20YL/RD 8 GROUND Z133 18BK/LG 9-10 - 11 - 12 - 13 - 14 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 15 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 16 TCC TEMPERATURE SIGNAL T819 20YL/VT 17 GROUND Z133 18BK/LG 18 - 19 SHIFT 4 CONTROL T811 20DG/LB 20 CAN C BUS (+) D65 20WT/LG 21 CAN C BUS (-) D64 20WT/LB 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9166 Pin Description Circuit 1 SHIFT 1 CONTROL T808 20DG/GY 2-3 SHIFT 3 CONTROL T810 20DG/DB 4-5 LINEAR 3 CONTROL T817 20YL/BR 6 LINEAR 1 GROUND T812 20DG/TN 7 LINEAR 1 CONTROL T813 20DG/LG 8 LINEAR 2 CONTROL T815 20YL/RD 9 LINEAR 2 GROUND T814 20YL/BR 10 PRESSURE SIGNAL 7 T806 20DG/VT 11 - 12 - 13 - 14 - - 15 LINEAR 3 GROUND T816 20YL/PK 16 TRS 1 SIGNAL T828 20DG/DB 17 TRS T42 SIGNAL T42 20DG/YL 18 TRS T3 SIGNAL T3 20DG/DB 19 TRS DRIVE SIGNAL T827 20DG/LB 20 TRS PARK SIGNAL T824 20YL/DB 21 TRS REVERSE SIGNAL T826 20DG/DB 22 SHIFT 2 CONTROL T809 20DG/YL 23 - 24 - 25 - 26 PRESSURE SIGNAL 8 T807 20DG/WT 27 - 28 TEMPERATURE SENSOR GROUND T820 20YL/WT 29 TRS NEUTRAL SIGNAL T825 20DG/YL 30 LINEAR 4 CONTROL T821 20YL/GY 31 LINEAR 4 GROUND T818 20YL/OR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9167 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description Control Module: Description and Operation Description DESCRIPTION On gasoline vehicles the Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). 68RFE TCM LOCATION Vehicles equipped 68RFE transmission and a 6.7L Diesel engine, the TCM is housed in the NGC4 controller utilizing only the C1 and C4 connectors (TCM only). The controller is located at the rear of the engine compartment, near the right inner fender. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 9170 AS68RC TCM LOCATION On Cab Chassis models equipped with the AS68RC transmission the Transmission Control Module (TCM) has three electrical connectors and is located in the passenger compartment underneath of the left side of the dash panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 9171 Control Module: Description and Operation Operation OPERATION RLE and RFE TRANSMISSIONS The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) (if equipped) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 9172 An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 9173 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 9174 SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 9175 AISIN AS68RC TRANSMISSION The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Speed Sensor - Output Speed Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 9176 - Manifold Pressure - Throttle position - Torque Reduction Confirmation - Engine Coolant Temperature - Exhaust Brake Status (if equipped) - PTO Request (if equipped) - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Exhaust Brake Cut Request (if equipped). - Solenoids. - Torque Reduction Request. Some examples of TCM .indirect outputs are: - Transmission Temperature (to PCM). - PRNDL Position (to cluster/CCN). - PTO Status. In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI). - Storing and selecting appropriate Shift Schedules. - System self-diagnostics. - Diagnostic capabilities (with scan tool). Clutch filling time is continuously maintained when the vehicle is running. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9181 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9182 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9183 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9184 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9185 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9186 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9187 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9188 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9189 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9190 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9191 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9192 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9193 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9194 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9195 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9196 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9197 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9198 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9199 Transmission Control System Relay: Connector Views Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > AS68RC Automatic Transmission Transmission Control System Relay: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION AS68RC Automatic Transmission NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. The relay is supplied fused B+ voltage, energized by the TIPM, and is used to supply power to the TCM when the transmission is in normal operating mode. Operation OPERATION The TIPM energizes the transmission control relay. When the relay is "off", no power is supplied to the TCM and the transmission will not operate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 68RFE Automatic Transmission Seals and Gaskets: Service and Repair 68RFE Automatic Transmission Removal REMOVAL 1. On 4WD vehicles remove the transfer case from the transmission, on 2WD vehicles remove the propeller shaft. 2. Using a pry tool, remove the output shaft seal. Installation INSTALLATION NOTE: On the 2WD models use Seal Installer 8154 with Handle C-4171. SEAL INSTALLER 10020 1. Clean the seal bore in the extension housing of any residue or particles remaining from the original seal. 2. Install new oil seal in the extension housing using Handle C-4171 (1) and Seal Installer 10020 (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 68RFE Automatic Transmission > Page 9206 Seals and Gaskets: Service and Repair 48RE Automatic Transmission Removal REMOVAL 1. Raise vehicle. 2. Mark propeller shaft and axle yoke for alignment reference. 3. Disconnect and remove propeller shaft. 4. Remove old seal with a screw mounted in a slide hammer. Installation INSTALLATION 1. Place seal in position on overdrive housing. 2. Drive seal into overdrive housing with Seal Installer 8154 (1) or 9037 (1) if equipped with a dust boot and Handle C-4171. 3. Carefully guide propeller shaft slip yoke into housing and onto output shaft splines. Align marks made at removal and connect propeller shaft to rear axle pinion yoke. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 68RFE Automatic Transmission > Page 9207 Seals and Gaskets: Service and Repair AS68RC Automatic Transmission Removal REMOVAL 1. Remove the transmission from the vehicle. 2. Remove the torque converter from the transmission torque converter housing. 3. Use a pry tool to remove oil pump seal. Installation INSTALLATION NOTE: Apply trans jell or petroleum jelly to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. 1. Clean and inspect oil pump seal seat. Then install seal using Converter Hub Seal Installer 9987. 2. Clean and inspect torque converter hub. If nicks, scratches or hub wear are found, torque converter replacement will be required. CAUTION: If the torque converter is being replaced, apply a light coating of grease to the crankshaft pilot hole. Also inspect the engine drive plate for cracks. If any cracks are found replace the drive plate. Do not attempt to repair a cracked drive plate. Always use new torque converter to drive plate bolts. 3. Apply a light film of MOPAR(R) AS68RC ATF oil to the torque converter hub and oil seal lips. Then install torque converter into transmission. Be sure that the hub lugs mesh with the front pump lugs when installing. 4. Install the transmission into the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Component ID: 410 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Description Circuit 1 SENSOR GROUND T160 20DG/WT Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 5 VOLT SUPPLY F856 20YL/PK 3 LINE PRESSURE SIGNAL T38 20YL/BR 4-- Component Location - 23 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 9212 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 9213 Fluid Pressure Sensor/Switch: Diagrams Component ID: 410 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Description Circuit 1 SENSOR GROUND T160 20DG/WT Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 5 VOLT SUPPLY F856 20YL/PK 3 LINE PRESSURE SIGNAL T38 20YL/BR 4-- Component Location - 23 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 9214 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description Fluid Pressure Sensor/Switch: Description and Operation Description DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, which is part of the pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the pump inlet. The system contains a Line Pressure Sensor, which is a direct input to the TCM. The line pressure sensor monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description > Page 9217 Fluid Pressure Sensor/Switch: Description and Operation Operation OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts, to ensure consistent shift quality. During all other operation, the desired line pressure value is adjusted based on torque level and other transmission requirements. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal Fluid Pressure Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal > Page 9220 Fluid Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations Overdrive Switch: Locations Component ID: 490 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Description Circuit 123 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 4 GROUND Z71 20LB/BK 5 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 6 SENSOR GROUND T160 20DG/WT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 9224 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 9225 Overdrive Switch: Diagrams Component ID: 490 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Description Circuit 123 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 4 GROUND Z71 20LB/BK 5 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 6 SENSOR GROUND T160 20DG/WT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 9226 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 9227 Overdrive Switch: Testing and Inspection DIAGNOSIS AND TESTING - OVERDRIVE ELECTRICAL CONTROLS The tow/haul overdrive off switch, valve body solenoid, case connectors and related wiring can all be tested with a 12 volt test lamp or a volt/ohmmeter. Check continuity of each component when diagnosis indicates this is necessary. Switch and solenoid continuity should be checked whenever the transmission fails to shift into fourth gear range. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Switch: Service and Repair 42RLE Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9230 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9231 Overdrive Switch: Service and Repair 545RFE Automatic Transmission Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9232 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9233 Overdrive Switch: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9234 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9235 Overdrive Switch: Service and Repair AS68RC Automatic Transmission Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9236 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9241 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9242 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9243 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9244 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9245 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9246 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9247 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9248 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9249 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9250 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9251 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9254 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9255 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9256 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9257 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9258 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9259 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9260 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9261 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9262 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9263 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9264 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9267 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9268 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9269 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9270 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 9271 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 9274 TRS REMOVAL/INSTALLATION 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 9275 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 9276 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 9277 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 9278 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed Transmission Speed Sensor: Locations Sensor-Input Speed Component ID: 405 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9283 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9284 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9285 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9286 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9287 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9288 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9289 Transmission Speed Sensor: Locations Sensor-Output Speed Component ID: 415 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9290 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9291 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9292 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9293 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 18DG/BR 2 SPEED SENSOR GROUND T13 18DG/VT Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9294 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9295 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9296 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9297 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9298 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9299 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9300 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9301 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed Transmission Speed Sensor: Diagrams Sensor-Input Speed Component ID: 405 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9304 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9305 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9306 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9307 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9308 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9309 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9310 Transmission Speed Sensor: Diagrams Sensor-Output Speed Component ID: 415 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9311 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9312 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9313 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9314 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 18DG/BR 2 SPEED SENSOR GROUND T13 18DG/VT Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9315 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9316 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9317 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9318 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9319 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9320 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9321 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9322 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Speed Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The speed sensor (1) is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Operation OPERATION Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. Signals from this sensor are shared with the powertrain control module. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9325 Transmission Speed Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9326 Transmission Speed Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION INPUT AND OUTPUT SPEED SENSORS The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate DC square wave signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the "teeth" of the gear pass by the sensor coil, an DC square wave is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an DC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Transmission Speed Sensor: Service and Repair 68RFE Automatic Transmission Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the transmission case. Installation INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9329 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. Installation INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9330 Transmission Speed Sensor: Service and Repair AS68RC Automatic Transmission Output Speed Sensor OUTPUT SPEED SENSOR OUTPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor. 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. Input Speed Sensor INPUT SPEED SENSOR INPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9331 3. Remove the wiring connector from the input speed sensor. 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. Output Speed Sensor OUTPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. OUTPUT SPEED SENSOR 1. Lubricate the output speed sensor O-ring with MOPAR(R) AS68RC ATF. 2. Install the output speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the wiring connector onto the output speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC ATF as necessary. Input Speed Sensor INPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9332 INPUT SPEED SENSOR 1. Lubricate the output speed sensor O-ring with MOPAR(R) AS68RC ATF. 2. Install the input speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the electrical wiring connector onto the input speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC as necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Component ID: 431 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 TCC TEMPERATURE SIGNAL T819 20YL/VT 2 TEMPERATURE SENSOR GROUND T820 20YL/WT Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 9336 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 9337 Transmission Temperature Sensor/Switch: Diagrams Component ID: 431 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 TCC TEMPERATURE SIGNAL T819 20YL/VT 2 TEMPERATURE SENSOR GROUND T820 20YL/WT Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 9338 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Component ID: 440 Component : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Connector: Name : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Color : BLACK # of pins : 2 Pin Description Circuit 1 BTSI SOLENOID CONTROL K32 18DB/YL 2 GROUND Z101 18BK/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 9343 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 9344 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 9345 Shift Interlock Solenoid: Diagrams Component ID: 440 Component : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Connector: Name : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Color : BLACK # of pins : 2 Pin Description Circuit 1 BTSI SOLENOID CONTROL K32 18DB/YL 2 GROUND Z101 18BK/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 9346 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 9347 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid Shift Solenoid: Locations Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 9352 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 9353 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 9354 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 9355 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 9356 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 9357 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 9358 Shift Solenoid: Locations Assembly-Transmission Solenoid/Pressure Switch Component ID: 17 Component : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH Color : LT. BROWN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 OD SOLENOID CONTROL T60 20YL/GY 2 UD CONTROL T59 20YL/LB 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 2-4 SOLENOID CONTROL T19 18YL/DB 5 2-4 PRESSURE SWITCH SENSE T47 18YL/DG 6 OD PRESSURE SIGNAL T9 20DG/TN 7 L/R CONTROL T20 20DG/WT 8-9-10 L/R PRESSURE SIGNAL T50 20YL/TN Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 9359 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 9360 Shift Solenoid: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 9361 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid Shift Solenoid: Diagrams Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 9364 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 9365 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 9366 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 9367 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 9368 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 9369 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 9370 Shift Solenoid: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 9371 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Description and Operation > Description Shift Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Description and Operation > Description > Page 9374 Shift Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > Removal Shift Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > Removal > Page 9377 Shift Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Shifter A/T: Description and Operation 42RLE Automatic Transmission Description DESCRIPTION The gear shift mechanism provides six shift positions which are: - Park (P) - Reverse (R) - Neutral (N) - Drive (D) - Manual second (2) - Manual low (1) Operation OPERATION MANUAL LOW (1) range provides FIRST gear only. Overrun braking is also provided in this range. MANUAL SECOND (2) range provides FIRST and SECOND gear only. DRIVE range provides FIRST, SECOND, THIRD and OVERDRIVE FOURTH gear ranges. The shift into OVERDRIVE FOURTH gear range occurs only after the transmission has completed the shift into D THIRD gear range. No further movement of the shift mechanism is required to complete the 3-4 shift. The FOURTH gear upshift occurs automatically when the overdrive selector switch is in the ON position. An upshift to FOURTH gear may not occur or may be delayed in some of the possible shift schedules. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 9382 Shifter A/T: Description and Operation 545RFE Automatic Transmission Description DESCRIPTION The gear shift mechanism provides six shift positions which are: - Park (P) - Reverse (R) - Neutral (N) - Drive (D) - Manual second (2) - Manual low (1) Operation OPERATION MANUAL LOW (1) range provides first gear only. Maximum engine braking is also provided in this range. MANUAL SECOND (2) range provides first and second gear only. DRIVE range provides FIRST, SECOND, THIRD, OVERDRIVE FOURTH, and OVERDRIVE FIFTH gear ranges. The shift into OVERDRIVE FOURTH and FIFTH gear ranges occurs only after the transmission has completed the shift into D THIRD gear range. No further movement of the shift mechanism is required to complete the 3-4 or 4-5 shifts. The FOURTH and FIFTH gear upshifts occur automatically unless the Tow/Haul or OD Off mode is enabled. No upshift to FOURTH or FIFTH gears will occur if any of the following are true: - The transmission fluid temperature is below 10° C (50° F) or above 121° C (250° F). - The shift to THIRD is not yet complete. - Vehicle speed is too low for the 3-4 or 4-5 shifts to occur. Upshifts into FOURTH or FIFTH will be delayed when the transmission fluid temperature is below 4.5° C (40° F) or above 115.5° C (240° F). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 9383 Shifter A/T: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The gear shift mechanism provides four shift positions which are: - Park (P) - Reverse (R) - Neutral (N) - Drive (D) Operation OPERATION Drive range provides underdrive FIRST, SECOND and THIRD gears, direct FOURTH gear and overdrive FIFTH and SIXTH gears. The shift into overdrive FIFTH and SIXTH gear occurs only after the transmission has completed the shift into FOURTH gear. No other movement of the shift mechanism is required to complete the 4-5 or 5-6 gear shifts. The FOURTH and FIFTH gear upshift occurs automatically unless the Tow/Haul mode is enabled. Upshifts into both overdrive gears, FIFTH and SIXTH, will be delayed when the transmission fluid temperature is below 4.5° C (40° F) or above 115.5° C (240° F). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 9384 Shifter A/T: Description and Operation 48RE Automatic Transmission Description DESCRIPTION The gear shift mechanism provides six shift positions which are: - PARK (P) - REVERSE (R) - NEUTRAL (N) - DRIVE (D) - Manual SECOND (2) - Manual LOW (1) Operation OPERATION Manual LOW (1) range provides first gear only. Overrun braking is also provided in this range. Manual SECOND (2) range provides first and second gear only. DRIVE range provides first, second, third, and overdrive fourth gear ranges. The shift into overdrive fourth gear range occurs only after the transmission has completed the shift into D third gear range. No further movement of the shift mechanism is required to complete the 3-4 shift. The fourth gear upshift occurs automatically when the overdrive selector switch is in the ON position. No upshift to fourth gear will occur if any of the following are true: - The transmission fluid temperature is below 10° C (50° F) or above 121° C (250° F). - The shift to third is not yet complete. - Vehicle speed is too low for the 3-4 shift to occur. - Battery temperature is below -5° C (23° F). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 9385 Shifter A/T: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION The gear shift mechanism provides seven shift positions which are: - Park (P) - Reverse (R) - Neutral (N) - Drive (D) - Manual Third (3) - Manual second (2) - Manual low (1) Operation OPERATION MANUAL LOW (1) range provides first gear only. Maximum engine braking is also provided in this range. MANUAL SECOND (2) range provides first and second gear only. MANUAL THIRD range provides first, second and third gear only. DRIVE range provides FIRST, SECOND, THIRD, FOURTH, OVERDRIVE FIFTH, OVERDRIVE SIXTH gear ranges. The shift into OVERDRIVE FOURTH and FIFTH gear ranges occurs only after the transmission has completed the shift into D THIRD gear range. The SIXTH gear upshifts occur automatically unless the Tow/Haul or OD Off mode is enabled. No upshift to FIFTH or SIXTH gears will occur if any of the following are true: - The transmission fluid temperature is below 5° C (41° F). - The shift to Fourth is not yet complete. - Vehicle speed is too low for the 4-5 or 5-6 shifts to occur. - Transfer case is in low range. Upshifts into FOURTH or FIFTH will be delayed when the transmission fluid temperature is below 4.5° C (40° F) or above 115.5° C (240° F). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Removal Shifter A/T: Service and Repair Removal REMOVAL 1. Remove the kneeblocker (2) and steering column opening reinforcement (1). 2. Remove the upper and lower column shrouds (1&2). 3. Loosen the column bolts and lower the column enough to allow clearance for the gear shift lever removal. 4. Disconnect the overdrive switch harness (3) (if equipped). 5. Disconnect the shift cable (2) from the shift lever. 6. Remove the gear shift lever mounting screws (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Removal > Page 9388 7. Remove the blocker pin (1) from the inhibit link slot (2) and remove the lever (3) by pulling forward toward the steering wheel and to the left then down. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Removal > Page 9389 Shifter A/T: Service and Repair Installation INSTALLATION 1. Install the lever assembly (3) reversing the way it came out using care to install the pin (2) in the blocker to slider slot (1). 2. The block inhibitor pin and spring (1) should seat into the slider slot (2). 3. Install the mounting screws (1) and tighten to 12 Nm (105 in. lbs.). 4. Cycle the key from ACC to RUN and ensure that the blocker does not stick or bind. 5. Turn the key to the OFF position and ensure that the shifter will not pull from the PARK position. 6. Connect the over drive switch harness (if equipped) (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Removal > Page 9390 NOTE: Route and tie off harness to original location. 7. Connect the shift cable to the lever (2). 8. Ensure the gear shift lever and transmission are in the PARK position and snap the cable adjust clip in place. 9. Install the upper and lower column shrouds (1&2). 10. Install the column back into place and tighten. 11. Install the kneeblocker (2) and steering column reinforcement cover (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > 42RLE Automatic Transmission Shift Cable: Testing and Inspection 42RLE Automatic Transmission DIAGNOSIS AND TESTING - GEARSHIFT CABLE 1. Engine starts must be possible with shift lever in PARK or NEUTRAL positions only. Engine starts must not be possible in any other gear position. 2. With the shift lever in the: a. PARK position - Apply upward force on the shift arm and remove pressure. Engine starts must be possible. b. PARK position - Apply downward force on the shift arm and remove pressure. Engine starts must be possible. c. NEUTRAL position - Normal position. Engine starts must be possible. d. NEUTRAL position - Engine running and brakes applied, apply upward force on the shift arm. Transmission shall not be able to shift from neutral to reverse. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > 42RLE Automatic Transmission > Page 9396 Shift Cable: Testing and Inspection 545RFE Automatic Transmission DIAGNOSIS AND TESTING - GEARSHIFT CABLE 1. Engine starts must be possible with shift lever in PARK or NEUTRAL positions only. Engine starts must not be possible in any other gear position. 2. With the shift lever in the: a. PARK position - Apply upward force on the shift arm and remove pressure. Engine starts must be possible. b. PARK position - Apply downward force on the shift arm and remove pressure. Engine starts must be possible. c. NEUTRAL position - Normal position. Engine starts must be possible. d. NEUTRAL position - Engine running and brakes applied, apply upward force on the shift arm. Transmission shall not be able to shift from neutral to reverse. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > 42RLE Automatic Transmission > Page 9397 Shift Cable: Testing and Inspection 68RFE Automatic Transmission DIAGNOSIS AND TESTING - GEARSHIFT CABLE 1. Engine starts must be possible with shift lever in PARK or NEUTRAL positions only. Engine starts must not be possible in any other gear position. 2. With the shift lever in the: a. PARK position - Apply upward force on the shift arm and remove pressure. Engine starts must be possible. b. PARK position - Apply downward force on the shift arm and remove pressure. Engine starts must be possible. c. NEUTRAL position - Normal position. Engine starts must be possible. d. NEUTRAL position - Engine running and brakes applied, apply upward force on the shift arm. Transmission shall not be able to shift from neutral to reverse. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > 42RLE Automatic Transmission > Page 9398 Shift Cable: Testing and Inspection 48RE Automatic Transmission DIAGNOSIS AND TESTING - GEARSHIFT CABLE 1. Engine starts must be possible with shift lever in PARK or NEUTRAL positions only. Engine starts must not be possible in any other gear position. 2. With the shift lever in the: a. PARK position - Apply upward force on the shift arm and remove pressure. Engine starts must be possible. b. PARK position - Apply downward force on the shift arm and remove pressure. Engine starts must be possible. c. NEUTRAL position - Normal position. Engine starts must be possible. d. NEUTRAL position - Engine running and brakes applied, apply upward force on the shift arm. Transmission shall not be able to shift from neutral to reverse. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > 42RLE Automatic Transmission > Page 9399 Shift Cable: Testing and Inspection AS68RC Automatic Transmission DIAGNOSIS AND TESTING - GEARSHIFT CABLE 1. Engine starts must be possible with shift lever in PARK or NEUTRAL positions only. Engine starts must not be possible in any other gear position. 2. With the shift lever in the: a. PARK position - Apply upward force on the shift arm and remove pressure. Engine starts must be possible. b. PARK position - Apply downward force on the shift arm and remove pressure. Engine starts must be possible. c. NEUTRAL position - Normal position. Engine starts must be possible. d. NEUTRAL position - Engine running and brakes applied, apply upward force on the shift arm. Transmission shall not be able to shift from neutral to reverse. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 68RFE Automatic Transmission Shift Cable: Adjustments 68RFE Automatic Transmission ADJUSTMENTS - GEARSHIFT CABLE NOTE: Always run the shift lever test using the scan tool to help diagnose a potential TRS problem Check adjustment by starting the engine in PARK and NEUTRAL. Adjustment is CORRECT if the engine starts only in these positions. Adjustment is INCORRECT if the engine starts in one but not both positions. If the engine starts in any position other than PARK or NEUTRAL, or if the engine will not start at all, the transmission range sensor may be faulty. Gearshift Adjustment Procedure 1. Shift transmission into PARK. 2. Release cable adjuster lock tab (3) (underneath the steering column) to unlock cable. 3. Raise vehicle. 4. Disengage the cable eyelet from the transmission manual shift lever. 5. Verify transmission shift lever is in PARK detent by moving lever fully rearward. Last rearward detent is PARK position. 6. Verify positive engagement of transmission park lock by attempting to rotate propeller shaft. Shaft will not rotate when park lock is engaged. 7. Snap the cable eyelet onto the transmission manual shift lever. 8. Lower vehicle. 9. Lock shift cable by pressing cable adjuster lock tab (3) downward until it snaps into place. 10. Check engine starting. Engine should start only in PARK and NEUTRAL. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 68RFE Automatic Transmission > Page 9402 Shift Cable: Adjustments 48RE Automatic Transmission ADJUSTMENTS - GEARSHIFT CABLE NOTE: Always run the shift lever test using the scan tool to help diagnose a potential TRS problem Check adjustment by starting the engine in PARK and NEUTRAL. Adjustment is CORRECT if the engine starts only in these positions. Adjustment is INCORRECT if the engine starts in one but not both positions. If the engine starts in any position other than PARK or NEUTRAL, or if the engine will not start at all, the transmission range sensor may be faulty. Gearshift Adjustment Procedure 1. Shift transmission into PARK. 2. Release cable adjuster lock tab (3) (underneath the steering column) to unlock cable. 3. Raise vehicle. 4. Disengage the cable eyelet from the transmission manual shift lever. 5. Verify transmission shift lever is in PARK detent by moving lever fully rearward. Last rearward detent is PARK position. 6. Verify positive engagement of transmission park lock by attempting to rotate propeller shaft. Shaft will not rotate when park lock is engaged. 7. Snap the cable eyelet onto the transmission manual shift lever. 8. Lower vehicle. 9. Lock shift cable by pressing cable adjuster lock tab (3) downward until it snaps into place. 10. Check engine starting. Engine should start only in PARK and NEUTRAL. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 68RFE Automatic Transmission > Page 9403 Shift Cable: Adjustments AS68RC Automatic Transmission ADJUSTMENTS - GEARSHIFT CABLE NOTE: Always run the shift lever test using the scan tool to help diagnose a potential TRS problem Check adjustment by starting the engine in PARK and NEUTRAL. Adjustment is CORRECT if the engine starts only in these positions. Adjustment is INCORRECT if the engine starts in one but not both positions. If the engine starts in any position other than PARK or NEUTRAL, or if the engine will not start at all, the transmission range sensor may be faulty. Gearshift Adjustment Procedure 1. Shift transmission into PARK. 2. Release cable adjuster lock tab (3) (underneath the steering column) to unlock cable. 3. Raise vehicle. 4. Disengage the cable eyelet from the transmission manual shift lever. 5. Verify transmission shift lever is in PARK detent by moving lever fully rearward. Last rearward detent is PARK position. 6. Verify positive engagement of transmission park lock by attempting to rotate propeller shaft. Shaft will not rotate when park lock is engaged. 7. Snap the cable eyelet onto the transmission manual shift lever. 8. Lower vehicle. 9. Lock shift cable by pressing cable adjuster lock tab (3) downward until it snaps into place. 10. Check engine starting. Engine should start only in PARK and NEUTRAL. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Shift Cable: Service and Repair 42RLE Automatic Transmission Removal REMOVAL 1. Shift transmission into PARK. 2. Raise vehicle. 3. Disengage cable (1) eyelet at transmission manual shift lever (3) and pull cable adjuster out of mounting bracket. 4. Lower the vehicle. 5. Remove the dash panel insulation pad as necessary to access the gearshift cable grommet (2). 6. Remove grommet (2) from the dash panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9406 Gearshift Cable at Steering Column 7. Remove any steering column (1) trim necessary to access the gearshift cable (2) and BTSI mechanism. 8. Disconnect the BTSI wiring connector (5). 9. Disconnect cable at lower column bracket and shift lever pin and pull the cable through the dash panel opening into the vehicle. 10. Remove gearshift cable (2) from vehicle. Installation INSTALLATION 1. Route the transmission end of the gearshift cable (1) through the opening in the dash panel. 2. Seat the cable grommet (2) into the dash panel opening. Gearshift Cable at Steering Column Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9407 3. Snap the cable into the steering column (1) bracket so the retaining ears are engaged and snap the cable eyelet onto the shift lever ball stud. 4. Raise the vehicle. 5. Place the transmission manual shift lever in the "PARK" detent (rearmost) position and rotate prop shaft to ensure transmission is in PARK. 6. Route the gearshift cable through the transmission mounting bracket and secure the cable by snapping the cable retaining ears into the transmission bracket and snapping the cable eyelet on the manual shift lever ball stud. 7. Lower vehicle. 8. Lock the shift cable adjustment by pressing the cable adjuster lock tab (3) downward until it snaps into place. 9. Check for proper operation of the transmission range sensor. 10. Adjust the gearshift cable, and BTSI mechanism. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9408 Shift Cable: Service and Repair 545RFE Automatic Transmission Removal REMOVAL 1. Shift transmission into PARK. 2. Raise vehicle. 3. Disengage cable (1) eyelet at transmission manual shift lever (3) and pull cable adjuster out of mounting bracket. 4. Lower the vehicle. 5. Remove the dash panel insulation pad as necessary to access the gearshift cable grommet (2). 6. Remove grommet (2) from the dash panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9409 7. Remove any steering column (1) trim necessary to access the gearshift cable (2) and BTSI mechanism. 8. Disconnect the BTSI wiring connector (5). 9. Disconnect cable at lower column bracket and shift lever pin and pull the cable through the dash panel opening into the vehicle. 10. Remove gearshift cable (2) from vehicle. Installation INSTALLATION 1. Route the transmission end of the gearshift cable (1) through the opening in the dash panel. 2. Seat the cable grommet (2) into the dash panel opening. 3. Snap the cable into the steering column (1) bracket so the retaining ears are engaged and snap the cable eyelet onto the shift lever ball stud. 4. Raise the vehicle. 5. Place the transmission manual shift lever in the "PARK" detent (rearmost) position and rotate prop shaft to ensure transmission is in PARK. 6. Route the gearshift cable through the transmission mounting bracket and secure the cable by snapping the cable retaining ears into the transmission bracket and snapping the cable eyelet on the manual shift lever ball stud. 7. Lower vehicle. 8. Lock the shift cable adjustment by pressing the cable adjuster lock tab (3) downward until it snaps into place. 9. Check for proper operation of the transmission range sensor. 10. Adjust the gearshift cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9410 Shift Cable: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Shift transmission into PARK. 2. Raise vehicle. 3. Disengage cable (1) eyelet at transmission manual shift lever (3) and pull cable adjuster out of mounting bracket. 4. Lower the vehicle. 5. Remove the dash panel insulation pad as necessary to access the gearshift cable grommet (2). 6. Remove grommet (2) from the dash panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9411 7. Remove any steering column (1) trim necessary to access the gearshift cable (2) and BTSI mechanism. 8. Disconnect the BTSI wiring connector (5). 9. Disconnect cable at lower column bracket and shift lever pin and pull the cable through the dash panel opening into the vehicle. 10. Remove gearshift cable (2) from vehicle. Installation INSTALLATION 1. Route the transmission end of the gearshift cable (1) through the opening in the dash panel. 2. Seat the cable grommet (2) into the dash panel opening. 3. Snap the cable into the steering column (1) bracket so the retaining ears are engaged and snap the cable eyelet onto the shift lever ball stud. 4. Raise the vehicle. 5. Place the transmission manual shift lever in the "PARK" detent (rearmost) position and rotate prop shaft to ensure transmission is in PARK. 6. Route the gearshift cable through the transmission mounting bracket and secure the cable by snapping the cable retaining ears into the transmission bracket and snapping the cable eyelet on the manual shift lever ball stud. 7. Lower vehicle. 8. Lock the shift cable adjustment by pressing the cable adjuster lock tab (3) downward until it snaps into place. 9. Check for proper operation of the transmission range sensor. 10. Adjust the gearshift cable and BTSI mechanism. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9412 Shift Cable: Service and Repair 68RFE Automatic Transmission Removal REMOVAL 1. Shift transmission into PARK. 2. Raise vehicle. 3. Disengage cable (1) eyelet at transmission manual shift lever (3) and pull cable adjuster out of mounting bracket. GEARSHIFT CABLE AT THE DASH PANE 4. Lower the vehicle. 5. Remove the dash panel insulation pad as necessary to access the gearshift cable grommet (2). 6. Remove grommet (2) from the dash panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9413 BRAKE TRANSMISSION INTERLOCK MEC 7. Remove any steering column (1) trim necessary to access the gearshift cable (2) and BTSI mechanism. 8. Disconnect the BTSI wiring connector (5). 9. Disconnect cable at lower column bracket and shift lever pin and pull the cable through the dash panel opening into the vehicle. 10. Remove gearshift cable (2) from vehicle. Installation INSTALLATION 1. Route the transmission end of the gearshift cable (1) through the opening in the dash panel. 2. Seat the cable grommet (2) into the dash panel opening. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9414 3. Snap the cable into the steering column (1) bracket so the retaining ears are engaged and snap the cable eyelet onto the shift lever ball stud. 4. Raise the vehicle. 5. Place the transmission manual shift lever in the "PARK" detent (rearmost) position and rotate prop shaft to ensure transmission is in PARK. 6. Route the gearshift cable through the transmission mounting bracket and secure the cable by snapping the cable retaining ears into the transmission bracket and snapping the cable eyelet on the manual shift lever ball stud. 7. Lower vehicle. 8. Lock the shift cable adjustment by pressing the cable adjuster lock tab (3) downward until it snaps into place. 9. Check for proper operation of the transmission range sensor. 10. Adjust the gearshift cable and BTSI mechanism. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9415 Shift Cable: Service and Repair AS68RC Automatic Transmission Removal REMOVAL 1. Shift transmission into PARK. 2. Raise vehicle. 3. Disconnect the shift cable ball socket (3) at transmission manual shift lever (4) and pull shift cable out of mounting bracket (1). 4. Lower the vehicle. 5. Remove the dash panel insulation pad as necessary to access the gearshift cable grommet (2). 6. Remove grommet (2) from the dash panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9416 7. Remove any steering column (1) trim necessary to access the gearshift cable (2) and BTSI mechanism. 8. Disconnect the BTSI wiring connector (5). 9. Disconnect cable at lower column bracket and shift lever pin and pull the cable through the dash panel opening into the vehicle. 10. Remove gearshift cable (2) from vehicle. Installation INSTALLATION 1. Route the transmission end of the gearshift cable (1) through the opening in the dash panel. 2. Seat the cable grommet (2) into the dash panel opening. 3. Snap the cable into the steering column (1) bracket so the retaining ears are engaged and snap the cable eyelet onto the shift lever ball stud. 4. Raise the vehicle. 5. Place the transmission manual shift lever in the "PARK" detent (rearmost) position and rotate prop shaft to ensure transmission is in PARK. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9417 6. Route the gearshift cable through the shift cable mounting bracket (1) and secure the cable by snapping the cable retaining ears into the bracket and by snapping the shift cable ball socket (3) onto the manual shift lever (4) ball stud. 7. Lower vehicle. 8. Lock the shift cable adjustment by pressing the cable adjuster lock tab (3) downward until it snaps into place. 9. Check for proper operation of the transmission range sensor. 10. Adjust the gearshift cable and BTSI mechanism. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description Temperature Warning Indicator - A/T: Description and Operation Description DESCRIPTION A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The transmission over-temperature indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Transmission Temperature in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The transmission over-temperature indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description > Page 9422 Temperature Warning Indicator - A/T: Description and Operation Operation OPERATION The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received over the Controller Area Network (CAN) data bus from the Powertrain Control Module (PCM). The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Indicator Lamp-On Message - Each time the cluster receives an electronic trans over-temp indicator lamp-ON message from the PCM indicating that the transmission fluid temperature is 135° C (275° F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the indicator is cycled OFF and then ON again by the appropriate lamp-ON and lamp-OFF messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the transmission over-temperature indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the instrument cluster illuminates the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission or the transmission cooling system are being overloaded, or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED,refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transmission temperature sensor, the PCM, the EMIC, the CAN data bus or the electronic communication related to transmission over-temperature indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Throttle Valve Solenoid, A/T > Component Information > Description and Operation Throttle Valve Solenoid: Description and Operation DESCRIPTION On vehicles equipped with a Cummins diesel engine, the transmission throttle valve cable has been replace by the transmission throttle valve actuator (TTVA). The TTVA consists of an electric DC motor, two potentiometers, and a gear drive system. The TTVA is mechanically connected to the transmission throttle valve in the valve body by the "D" shaped opening in the bottom of the TTVA shaft. Changes in the TTVA position are therefore transferred to the throttle valve and cause changes in the transmission throttle pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Throttle Valve Solenoid, A/T > Component Information > Description and Operation > Page 9427 Throttle Valve Solenoid: Adjustments ADJUSTMENT The Transmission Throttle Valve Actuator (TTVA) does not require any mechanical adjustments. All changes in throttle valve position are controlled by the Engine Control Module (ECM). The TTVA does require an initialization period after the actuator has been removed or replaced. After the actuator has been removed or replaced, move the ignition to the ON position for thirty (30) seconds. This will allow the ECM sufficient time to perform the internal calibration procedures to learn the TTVA's current "zero" position. Once this is done, check the ECM for diagnostic trouble codes (DTCs). If no DTCs are set relating to the TTVA, the TTVA is fully calibrated and ready for use. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Throttle Valve Solenoid, A/T > Component Information > Service and Repair > Removal Throttle Valve Solenoid: Service and Repair Removal REMOVAL 1. Remove the bolts (2) holding the transmission throttle valve actuator (TTVA) (1) to the transmission case. 2. Allow the TTVA (1) to rotate clockwise away from the transmission. 3. Remove the wiring connector (2) from the TTVA (1). 4. Lift the TTVA (1) straight upward and off the throttle valve shaft (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Throttle Valve Solenoid, A/T > Component Information > Service and Repair > Removal > Page 9430 Throttle Valve Solenoid: Service and Repair Installation INSTALLATION 1. Position the transmission throttle valve actuator (TTVA) (1) over the throttle valve shaft (3). 2. Align the D-shaped opening in the bottom of the TTVA to the throttle valve shaft and install the TTVA onto the shaft. 3. Install the wiring connector (2) to the TTVA (1). 4. Rotate the TTVA (1) to the transmission case and install the bolts (2) to hold the TTVA to the transmission. 5. Tighten the bolts to 8.5 Nm (75 in.lbs.). 6. Initialize the TTVA. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Description and Operation Throttle Valve Cable/Linkage: Description and Operation DESCRIPTION Transmission throttle valve cable (1) adjustment is extremely important to proper operation. This adjustment positions the throttle valve, which controls shift speed, quality, and part-throttle downshift sensitivity. If cable setting is too loose, early shifts and slippage between shifts may occur. If the setting is too tight, shifts may be delayed and part throttle downshifts may be very sensitive. The transmission throttle valve is operated by a cam on the throttle lever. The throttle lever is operated by an adjustable cable (3). The cable is attached to an arm mounted on the throttle lever shaft. A retaining clip (2) at the engine-end of the cable is removed to provide for cable adjustment. The retaining clip is then installed back onto the throttle valve cable to lock in the adjustment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Description and Operation > Page 9434 Throttle Valve Cable/Linkage: Adjustments ADJUSTMENTS - THROTTLE VALVE CABLE A correctly adjusted throttle valve cable (1) will cause the throttle lever on the transmission to move simultaneously with the throttle body lever (3) from the idle position. Proper adjustment will allow simultaneous movement without causing the transmission throttle lever to either move ahead of, or lag behind the lever on the throttle body. ADJUSTMENT VERIFICATION 1. Turn ignition key to OFF position. 2. Remove air cleaner. 3. Verify that lever on throttle body is at curb idle position. Then verify that the transmission throttle lever is also at idle (fully forward) position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Description and Operation > Page 9435 4. Slide cable off attachment stud on throttle body lever. 5. Compare position (B) of cable end to attachment stud on throttle body lever: - Cable end and attachment stud should be aligned (or centered on one another) to within 1 mm (0.039 in.) in either direction (B). - If cable end and attachment stud are misaligned (off center), cable will have to be adjusted as described in Throttle Valve Cable Adjustment procedure. 6. Reconnect cable end to attachment stud. Then with aid of a helper, observe movement of transmission throttle lever and lever on throttle body. - If both levers move simultaneously from idle to half-throttle and back to idle position, adjustment is correct. - If transmission throttle lever moves ahead of, or lags behind throttle body lever, cable adjustment will be necessary. Or, if throttle body lever prevents transmission lever from returning to closed position, cable adjustment will be necessary. ADJUSTMENT PROCEDURE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Description and Operation > Page 9436 1. Turn ignition switch to OFF position. 2. Remove air cleaner if necessary. 3. Disconnect cable end (3) from attachment stud on throttle lever (1). Carefully slide cable off stud. Do not pry or pull cable off. 4. Verify that transmission throttle lever is in fully closed position. Then be sure lever on throttle body is at curb idle position. 5. Pry the T.V. cable lock (A) into the UP position. This will unlock the cable and allow for readjustment. 6. Apply just enough tension on the T.V. cable (B) to remove any slack in the cable. Pulling too tight will cause the T.V. lever on the transmission to move out of its idle position, which will result in an incorrect T.V. cable adjustment. Slide the sheath of the T.V. cable (D) back and forth until the centerlines of the T.V. cable end (B) and the throttle bell crank lever (C) are aligned within one millimeter (1mm). 7. While holding the T.V. cable in the set position push the T.V. cable lock (A) into the down position. This will lock the present T.V. cable adjustment. NOTE: Be sure that as the cable is pulled forward and centered on the throttle lever stud, the cable housing moves smoothly with the cable. Due to the angle at which the cable housing enters the spring housing, the cable housing may bind slightly and create an incorrect adjustment. 8. Reconnect the T.V. cable (B) to the throttle bellcrank lever (C). 9. Check cable adjustment. Verify transmission throttle lever and lever on throttle body move simultaneously. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed Torque Converter: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The torque converter is a hydraulic device that couples the engine crankshaft to the transmission. The torque converter consists of an outer shell with an internal turbine (1), a stator (4), an overrunning clutch, an impeller (2), and an electronically applied converter clutch (6). The converter clutch provides reduced engine speed and greater fuel economy when engaged. Clutch engagement also provides reduced transmission fluid temperatures. The torque converter hub drives the transmission oil (fluid) pump. The torque converter is a sealed, welded unit that is not repairable and is serviced as an assembly. CAUTION: The torque converter must be replaced if a transmission failure resulted in large amounts of metal or fiber contamination in the fluid. IMPELLER Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9441 Impeller The impeller is an integral part of the converter housing. The impeller consists of curved blades placed radially along the inside of the housing on the transmission side of the converter. As the converter housing is rotated by the engine, so is the impeller, because they are one and the same and are the driving members of the system. TURBINE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9442 Turbine The turbine is the output, or driven, member of the converter. The turbine is mounted within the housing opposite the impeller, but is not attached to the housing. The input shaft is inserted through the center of the impeller and splined into the turbine. The design of the turbine is similar to the impeller, except the blades of the turbine are curved in the opposite direction. STATOR The stator assembly is mounted on a stationary shaft which is an integral part of the oil pump. The stator contains an over-running clutch (1-4), which allows the stator to rotate only in a clockwise direction. When the stator is locked against the over-running clutch, the torque multiplication feature of the Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9443 torque converter is operational. The stator (1) is located between the impeller (2) and turbine (4) within the torque converter case. TORQUE CONVERTER CLUTCH (TCC) The TCC was installed to improve the efficiency of the torque converter that is lost to the slippage of the fluid coupling. Although the fluid coupling provides smooth, shock-free power transfer, it is natural for all fluid couplings to slip. If the impeller and turbine were mechanically locked together, a zero slippage condition could be obtained. A hydraulic piston (6) was added to the turbine (5), and a friction material (7) was added to the inside of the front cover (1) to provide this mechanical lock-up. Operation OPERATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9444 Torque Converter Fluid Operation The converter impeller (driving member), which is integral to the converter housing and bolted to the engine drive plate, rotates at engine speed. The converter turbine (driven member), which reacts from fluid pressure generated by the impeller, rotates and turns the transmission input shaft. TURBINE As the fluid that was put into motion by the impeller blades strikes the blades of the turbine, some of the energy and rotational force is transferred into the turbine and the input shaft. This causes both of them (turbine and input shaft) to rotate in a clockwise direction following the impeller. As the fluid is leaving the trailing edges of the turbine's blades it continues in a "hindering" direction back toward the impeller. If the fluid is not redirected before it strikes the impeller, it will strike the impeller in a direction that would tend to slow it down. STATOR Stator Operation Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9445 Torque multiplication is achieved by locking the stator's over-running clutch to its shaft. Under stall conditions the turbine is stationary and the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counterclockwise direction. When this happens the overrunning clutch of the stator locks and holds the stator from rotating. With the stator locked, the oil strikes the stator blades (1) and is redirected into a "helping" direction before it enters the impeller. This circulation of oil from impeller to turbine, turbine to stator, and stator to impeller, can produce a maximum torque multiplication of about 1.75:1. As the turbine begins to match the speed of the impeller, the fluid that was hitting the stator in such as way as to cause it to lock-up is no longer doing so. In this condition of operation, the stator begins to free wheel and the converter acts as a fluid coupling. TORQUE CONVERTER CLUTCH (TCC) The torque converter clutch is hydraulically applied or released when fluid is feed or vented from the hydraulic circuit by the torque converter control (TCC) solenoid on the valve body. The torque converter clutch is controlled by the Powertrain Control Module (PCM). The torque converter clutch engages in FOURTH gear, and in THIRD gear under various conditions, such as when the O/D switch is OFF, or when the vehicle is cruising on a level surface after the vehicle has warmed up. The torque converter clutch can also be engaged in the MANUAL SECOND gear position if high transmission temperatures are sensed by the PCM. The torque converter clutch may disengage momentarily when an increase in engine load is sensed by the PCM, such as when the vehicle begins to go uphill or the throttle pressure is increased. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9446 Torque Converter: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The torque converter is a hydraulic device that couples the engine crankshaft to the transmission. The torque converter consists of an outer shell with an internal turbine (1), a stator (2), an overrunning clutch, an impeller (5), and an electronically applied converter clutch (6). The converter clutch provides reduced engine speed and greater fuel economy when engaged. Clutch engagement also provides reduced transmission fluid temperatures. The torque converter hub (3) drives the transmission oil (fluid) pump and contains an O-ring seal (4) to better control oil flow. The torque converter is a sealed, welded unit that is not repairable and is serviced as an assembly. CAUTION: The torque converter must be replaced if a transmission failure resulted in large amounts of metal or fiber contamination in the fluid. IMPELLER Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9447 The impeller is an integral part of the converter housing. The impeller consists of curved blades placed radially along the inside of the housing on the transmission side of the converter. As the converter housing is rotated by the engine, so is the impeller, because they are one and the same and are the driving members of the system. TURBINE The turbine is the output, or driven, member of the converter. The turbine is mounted within the housing opposite the impeller, but is not attached to the housing. The input shaft is inserted through the center of the impeller and splined into the turbine. The design of the turbine is similar to the impeller, except the blades of the turbine are curved in the opposite direction. STATOR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9448 The stator assembly is mounted on a stationary shaft which is an integral part of the oil pump. The stator (1) is located between the impeller (2) and the turbine (4) within the torque converter case. The stator contains an over-running clutch (1-4), which allows the stator to rotate only in a clockwise direction. When the stator is locked against the over-running clutch, the torque multiplication feature of the torque converter is operational. TORQUE CONVERTER CLUTCH (TCC) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9449 The TCC was installed to improve the efficiency of the torque converter that is lost to the slippage of the fluid coupling. Although the fluid coupling provides smooth, shock-free power transfer, it is natural for all fluid couplings to slip. If the impeller (3) and turbine (5) were mechanically locked together, a zero slippage condition could be obtained. A hydraulic piston (6) with friction material (7) was added to the turbine assembly (5) to provide this mechanical lock-up. In order to reduce heat build-up in the transmission and buffer the powertrain against torsional vibrations, the TCM can duty cycle the L/R-CC Solenoid to achieve a smooth application of the torque converter clutch. This function, referred to as Electronically Modulated Converter Clutch (EMCC) can occur at various times depending on the following variables: - Shift lever position - Current gear range - Transmission fluid temperature - Engine coolant temperature - Input speed - Throttle angle - Engine speed Operation OPERATION The converter impeller (driving member), which is integral to the converter housing and bolted to the engine drive plate, rotates at engine speed. The converter turbine (driven member), which reacts from fluid pressure generated by the impeller, rotates and turns the transmission input shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9450 TURBINE As the fluid that was put into motion by the impeller blades strikes the blades of the turbine, some of the energy and rotational force is transferred into the turbine and the input shaft. This causes both of them (turbine and input shaft) to rotate in a clockwise direction following the impeller. As the fluid is leaving the trailing edges of the turbine's blades it continues in a "hindering" direction back toward the impeller. If the fluid is not redirected before it strikes the impeller, it will strike the impeller in such a direction that it would tend to slow it down. STATOR Torque multiplication is achieved by locking the stator's over-running clutch to its shaft. Under stall conditions (the turbine is stationary), the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counterclockwise direction. When this happens the over-running clutch of the stator locks and holds the stator from rotating. With the stator locked, the oil strikes the stator blades and is redirected into a "helping" direction before it enters the impeller. This circulation of oil from impeller to turbine, turbine to stator, and stator to impeller, can produce a maximum torque multiplication of about 1.75:1. As the turbine begins to match the speed of the impeller, the fluid that was hitting the stator in such as way as to cause it to lock-up is no longer doing so. In this condition of operation, the stator begins to free wheel and the converter acts as a fluid coupling. TORQUE CONVERTER CLUTCH (TCC) In a standard torque converter, the impeller and turbine are rotating at about the same speed and the stator is freewheeling, providing no torque multiplication. By applying the turbine's piston and friction material to the front cover, a total converter engagement can be obtained. The result of this engagement is a direct 1:1 mechanical link between the engine and the transmission. The clutch can be engaged in all gear ranges except first depending on the Tow/Haul and ERS status. In normal operation, the clutch will engage after the shift to fourth gear. If the Tow/Haul mode is enabled, the clutch will engage after the shift to third (direct) gear. The TCM controls the torque converter clutch via the L/R-CC Solenoid. There are four TCC operational modes: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9451 - No EMCC - Partial EMCC - Full EMCC - Gradual EMCC Release NO EMCC Under No EMCC conditions, the L/R Solenoid is OFF. There are several conditions that can result in NO EMCC operations. No EMCC can be initiated due to a fault in the transmission or because the TCM does not see the need for EMCC under current driving conditions. PARTIAL EMCC Partial EMCC operation modulates the L/R Solenoid (duty cycle) to obtain partial torque converter clutch application. Partial EMCC operation is maintained until Full EMCC is called for and actuated. During Partial EMCC some slip does occur. Partial EMCC will usually occur at low speeds, low load and light throttle situations. FULL EMCC During Full EMCC operation, the TCM increases the L/R Solenoid duty cycle to full ON after Partial EMCC control brings the engine speed within the desired slip range of transmission input speed relative to engine rpm. GRADUAL EMCC RELEASE This operation is to soften the change from Full or Partial EMCC to No EMCC. This is done at mid-throttle by slowly decreasing the L/R Solenoid duty cycle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9452 Torque Converter: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION The torque converter is a hydraulic device that couples the engine crankshaft to the transmission. The torque converter consists of an outer shell with an lock-up damper (1), lock-up piston (3 ), pump impeller (4), turbine runner (5), stator (6), and one-way clutch (7). The converter clutch provides reduced engine speed and greater fuel economy when engaged. Clutch engagement also provides reduced transmission fluid temperatures. The torque converter is a sealed, welded unit that is not repairable and is serviced as an assembly. CAUTION: The torque converter must be replaced if a transmission failure resulted in large amounts of metal or fiber contamination in the fluid. IMPELLER Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9453 Impeller The impeller is an integral part of the converter housing. The impeller consists of curved blades placed radially along the inside of the housing on the transmission side of the converter. As the converter housing is rotated by the engine, so is the impeller, because they are one and the same and are the driving members of the system. TURBINE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9454 Turbine The turbine is the output, or driven, member of the converter. The turbine is mounted within the housing opposite the impeller, but is not attached to the housing. The input shaft is inserted through the center of the impeller and splined into the turbine. The design of the turbine is similar to the impeller, except the blades of the turbine are curved in the opposite direction. STATOR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9455 The stator assembly is mounted on a stationary shaft which is an integral part of the oil pump. The stator (1) is located between the impeller (2) and the turbine (4) within the torque converter case. The stator contains an one-way clutch (1-4), which allows the stator to rotate only in a clockwise direction. When the stator is locked against the over-running clutch, the torque multiplication feature of the torque converter is operational. Torque Converter Solenoid In order to reduce heat build-up in the transmission and buffer the powertrain against torsional vibrations, the TCM can duty cycle the Torque Converter Solenoid to achieve a smooth application of the torque converter clutch. This function can occur at various times depending on the following variables: - Shift lever position - Current gear range - Transmission fluid temperature - Engine coolant temperature - Input speed - Throttle angle - Engine speed Operation OPERATION The torque converter transmits engine torque to the transmission. When it is not locked up, it transmits the torque by means of oil. When it is locked up, it transmits the torque by means of the lockup piston. The lockup damper is designed to soften the impact as the torque converter locks up. The torque converter is a 3-element, single-stage, 2-phase type. The term single-stage indicates that there is 1 turbine runner (output element). The term 2-phase indicates that the mechanism works as a torque converter when the turbine runner is turning slowly relative to the pump impeller and as a fluid coupling when the turbine runner is turning quickly relative to the pump impeller. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9456 TORQUE CONVERTER NOT LOCKED UP The torque converter activation pressure is not supplied between the converter front cover and lockup piston via passage (3). The lockup clutch (1) and the plate (2) are therefore disengaged and the lockup function is inactive. TORQUE CONVERTER LOCKED UP Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9457 The torque converter activation pressure is supplied between the converter front cover and lockup piston via passage (3). The lockup clutch (1) and the plate (2) are therefore engaged and the lockup function is active. TURBINE As the fluid that was put into motion by the impeller blades strikes the blades of the turbine, some of the energy and rotational force is transferred into the turbine and the input shaft. This causes both of them (turbine and input shaft) to rotate in a clockwise direction following the impeller. As the fluid is leaving the trailing edges of the turbine's blades it continues in a "hindering" direction back toward the impeller. If the fluid is not redirected before it strikes the impeller, it will strike the impeller in such a direction that it would tend to slow it down. STATOR Torque multiplication is achieved by locking the stator's one-way clutch to its shaft. Under stall conditions (the turbine is stationary), the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counterclockwise direction. When this happens the one-way clutch of the stator locks and holds the stator from rotating. With the stator locked, the oil strikes the stator blades and is redirected into a "helping" direction before it enters the impeller. This circulation of oil from impeller to turbine, turbine to stator, and stator to impeller, can produce a maximum torque multiplication of about 2.4:1. As the turbine begins to match the speed of the impeller, the fluid that was hitting the stator in such as way as to cause it to lock-up is no longer doing so. In this condition of operation, the stator begins to free wheel and the converter acts as a fluid coupling. Stator Operation Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9458 TORQUE CONVERTER CLUTCH (TCC) In a standard torque converter, the impeller and turbine are rotating at about the same speed and the stator is freewheeling, providing no torque multiplication. By applying the turbine's piston and friction material to the front cover, a total converter engagement can be obtained. The result of this engagement is a direct 1:1 mechanical link between the engine and the transmission. The clutch can be engaged in second, third, fourth, fifth and, sixth gear ranges. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > 48RE (A-618) 4 Speed Torque Converter: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Remove transmission and torque converter from vehicle. 2. Place a suitable drain pan under the converter housing end of the transmission. CAUTION: Verify that transmission is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission. 3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the torque converter from the transmission. Installation INSTALLATION Check converter hub and drive notches for sharp edges, burrs, scratches, or nicks. Polish the hub and notches with 320/400 grit paper or crocus cloth if necessary. The hub must be smooth to avoid damaging the pump seal at installation. 1. Lubricate oil pump seal lip with transmission fluid. 2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or bushing while inserting torque converter into the front of the transmission. 3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. 6. Check converter seating with a scale (1) and straightedge (2). Surface of converter lugs should be 19mm (0.75 in.) to the rear of the straightedge when converter is fully seated. 7. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 8. Install the transmission in the vehicle. 9. Fill the transmission with the recommended fluid. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > 48RE (A-618) 4 Speed > Page 9461 Torque Converter: Service and Repair 68RFE Automatic Transmission Removal REMOVAL 1. Remove transmission and torque converter from vehicle. 2. Place a suitable drain pan under the converter housing end of the transmission. CAUTION: Verify that transmission is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission. 3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the torque converter from the transmission. Installation INSTALLATION NOTE: Check converter hub and drive flats for sharp edges, burrs, scratches, or nicks. Polish the hub and flats with 800/1000 grit paper or crocus cloth if necessary. Verify that the converter hub O-ring is properly installed and is free from debris. The hub must be smooth to avoid damaging the pump seal at installation. 1. Lubricate oil pump seal lip with transmission fluid. 2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or converter hub O-ring while inserting torque converter into the front of the transmission. 3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. 6. Check converter seating with a scale (1) and straightedge (2). Surface of converter lugs should be at least 25 mm (1in.) to rear of straightedge when converter is fully seated. 7. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 8. Install the transmission in the vehicle. 9. Fill the transmission with the recommended fluid. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > 48RE (A-618) 4 Speed > Page 9462 Torque Converter: Service and Repair AS68RC Automatic Transmission Removal REMOVAL 1. Remove transmission from vehicle. 2. Place a suitable drain pan under the converter housing end of the transmission. WARNING: Be certain the transmission is secure when removing the torque converter, the torque converter is very heavy. Failure to follow these instructions may result in personal injury or may be fatal. TC REMOVAL 3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the torque converter from the transmission. Installation INSTALLATION NOTE: Check converter hub and drive flats for sharp edges, burrs, scratches, or nicks. Polish the hub and flats with 800/10000 grit paper or crocus cloth if necessary. Verify that the oil pump seal is properly installed and is free from debris. The hub must be smooth to avoid damaging the pump seal at installation. TC REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > 48RE (A-618) 4 Speed > Page 9463 1. Lubricate oil pump seal lip and input shaft seal rings with MOPAR(R) AS68RC ATF. WARNING: Be certain the transmission is secure when installing the torque converter, the torque converter is very heavy. Failure to follow these instructions may result in personal injury or may be fatal. 2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or input shaft seal rings while inserting torque converter into the front of the transmission. 3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. 6. Install the transmission into the vehicle. 7. Check converter seating with a scale (1) and straightedge (2). Surface of converter lugs should be at least 28.2 mm (1.12 in.) to rear of straightedge when converter is fully seated. 8. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 9. Install the transmission in the vehicle. 10. Fill the transmission with the recommended fluid. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Description and Operation > Description Torque Converter Check Valve: Description and Operation Description DIESEL ENGINE The converter drainback check valve is located in the in the TOC pressure - supply line, between the engine mounted TOC and the air to oil TOC. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Description and Operation > Description > Page 9468 Torque Converter Check Valve: Description and Operation Operation DIESEL ENGINE The valve prevents fluid from draining from the converter into the cooler and lines when the vehicle is shut down for lengthy periods. Production valves have pipe thread on one end, while the opposite end is threaded for a flare fitting, and are threaded into the oil cooler mounted on the side of the engine. All valves have an arrow (or similar mark) to indicate direction of flow through the valve. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Description and Operation > Page 9469 Torque Converter Check Valve: Service and Repair DIESEL ENGINE The converter drainback check valve is located in the in the TOC pressure - supply line, between the engine mounted transmission oil cooler and the air to oil transmission oil cooler. The valve prevents fluid drainback when the vehicle is parked for lengthy periods. The valve check ball is spring loaded and has an opening pressure of approximately 2 psi. The valve is serviced as an assembly; it is not repairable. Do not clean the valve if restricted, or contaminated by sludge, or debris. If the valve fails, or if a transmission malfunction occurs that generates significant amounts of sludge and/or clutch particles and metal shavings, the valve must be replaced. If the valve is restricted, installed backwards, or in the wrong line, it will cause an transmission overheating condition and possible transmission failure. CAUTION: The drainback valve is a one-way flow device. It must be properly oriented in terms of flow direction for the cooler to function properly. The valve must be installed in the pressure line. Otherwise flow will be blocked and would cause an transmission overheating condition and eventual transmission failure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9474 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9475 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9476 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9477 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9478 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9479 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9480 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9481 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9482 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9483 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9484 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9485 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9486 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9487 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9488 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9489 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9490 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9491 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9492 Transmission Control System Relay: Connector Views Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Description and Operation > AS68RC Automatic Transmission Transmission Control System Relay: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION AS68RC Automatic Transmission NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. The relay is supplied fused B+ voltage, energized by the TIPM, and is used to supply power to the TCM when the transmission is in normal operating mode. Operation OPERATION The TIPM energizes the transmission control relay. When the relay is "off", no power is supplied to the TCM and the transmission will not operate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Description and Operation > All Vehicles Transmission Cooler: Description and Operation All Vehicles ALL VEHICLES An air-to-oil transmission oil cooler is standard on all engine packages. The transmission oil cooler is mounted to the front of the radiator above the power steering cooler and Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Description and Operation > All Vehicles > Page 9499 Transmission Cooler: Description and Operation Diesel DIESEL The 5.9L diesel models equipped with an automatic transmission are equipped with a water-to-oil cooler and a separate air-to-oil cooler. Both coolers are supplied as standard equipment on diesel engine powered models when equipped with an automatic transmission. The water-to-oil transmission oil cooler is mounted to a bracket on the intake side of the engine. The 6.7L model diesel with automatic transmission is equipped with an air-to-oil cooler only. This cooler is located in front of the radiator. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Transmission Oil Cooler Transmission Cooler: Service and Repair Transmission Oil Cooler Air To Oil Cooler - Diesel AIR TO OIL COOLER - DIESEL 1. Remove Charge Air Cooler. 2. Place a drain pan under the oil cooler. 3. Raise the vehicle. 4. Disconnect the oil cooler quick-connect fittings from the transmission lines. 5. Remove the charge air cooler-to-oil cooler bolt. 6. Remove two mounting nuts. 7. Remove the oil cooler and line assembly towards the front of vehicle. Cooler must be rotated and tilted into position while removing. Water To Oil Cooler REMOVAL - WATER TO OIL COOLER CAUTION: If a leak should occur in the water-to-oil cooler mounted to the side of the engine block, engine coolant may become mixed with transmission fluid. Transmission fluid may also enter engine cooling system. Both cooling system and transmission should be drained and inspected in case of oil cooler leakage. 1. Disconnect both battery negative cables. 2. Remove starter. 3. Drain cooling system. 4. Disconnect coolant lines from cooler. NOTE: Use a back-up wrench on the transmission cooler fittings to prevent damage to the cooler. 5. Disconnect transmission oil lines from cooler. Plug cooler lines to prevent oil leakage. 6. Remove cooler bracket to transmission adapter bolt. 7. Remove wire harness push in clip at bottom of coolant bracket. 8. Remove wire harness push in clip at bottom of coolant bracket. 9. Remove two cooler bracket to block bolts. 10. Remove cooler assembly from vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Transmission Oil Cooler > Page 9502 Air To Oil Cooler - Diesel AIR TO OIL COOLER - DIESEL 1. Carefully position the oil cooler assembly to the vehicle. 2. Install two nuts and one bolt. Tighten to 11 Nm (95 in. lbs.) torque. 3. Connect the quick-connect fittings to the transmission cooler lines. 4. Install Charge Air Cooler. 5. Start the engine and check all fittings for leaks. 6. Check the fluid level in the automatic transmission. Water-To-Oil Cooler INSTALLATION - WATER-TO-OIL COOLER Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Transmission Oil Cooler > Page 9503 1. Position oil cooler on cylinder block. 2. Install 2 capscrews to cylinder block finger tight. 3. Install capscrews at the transmission adapter. Torque bolt to 24 Nm (18 ft. lbs.) 4. Tighten lower mounting bolt to cooler at the cylinder block. Tighten to 77 Nm (57 ft. lbs.). NOTE: Use a back-up wrench on the transmission cooler fittings to prevent damage to the cooler. 5. Tighten upper mounting bolt to cooler at cylinder block to 24 N.m (18 ft. lbs). 6. Install wire harness push in clip at bottom of cooler bracket. 7. Install starter motor. 8. Connect battery negative cables. 9. Fill cooling system. 10. Check transmission oil level and fill as necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Transmission Oil Cooler > Page 9504 Transmission Cooler: Service and Repair Transmission Oil Cooler Lines TRANSMISSION COOLER LINE QUICK CONNECT FITTING DISASSEMBLY/ASSEMBLY DISCONNECT 1. Remove dust cap by pulling it straight back off of quick connect fitting. 2. Place disconnect tool Special Tool 8875A onto transmission cooler line with the fingers of the tool facing the quick connect fitting. 3. Slide disconnect tool down the transmission line and engage the fingers of the tool into the retaining clip. When properly engaged in the clip, the tool will fit flush against the quick connect fitting. 4. Rotate the disconnect tool 60° to expand the retaining clip. 5. While holding the disconnect tool against the quick connect fitting, pull back on the transmission cooler line to remove. CONNECT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Transmission Oil Cooler > Page 9505 1. Align transmission cooler line with quick connect fitting while pushing straight into the fitting. 2. Push in on transmission cooler line until a "click" is heard or felt. 3. Slide dust cap down the transmission cooler line and snap it over the quick connect fitting until it is fully seated and rotates freely. Dust cap will only snap over quick connect fitting when the transmission cooler line is properly installed. NOTE: If dust cap will not snap into place, repeat assembly step 2. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9510 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9511 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9512 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9513 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9514 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9515 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9516 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9517 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9518 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9519 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9520 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9523 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9524 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9525 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9526 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9527 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9528 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9529 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9530 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9531 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9532 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9533 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9536 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9537 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9538 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9539 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 9540 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 9543 TRS REMOVAL/INSTALLATION 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 9544 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 9545 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 9546 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 9547 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed Transmission Speed Sensor: Locations Sensor-Input Speed Component ID: 405 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9552 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9553 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9554 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9555 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9556 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9557 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9558 Transmission Speed Sensor: Locations Sensor-Output Speed Component ID: 415 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9559 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9560 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9561 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9562 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 18DG/BR 2 SPEED SENSOR GROUND T13 18DG/VT Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9563 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9564 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9565 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9566 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9567 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9568 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9569 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9570 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed Transmission Speed Sensor: Diagrams Sensor-Input Speed Component ID: 405 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9573 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9574 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9575 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9576 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9577 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9578 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9579 Transmission Speed Sensor: Diagrams Sensor-Output Speed Component ID: 415 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9580 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9581 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9582 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9583 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 18DG/BR 2 SPEED SENSOR GROUND T13 18DG/VT Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9584 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9585 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9586 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9587 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9588 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9589 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9590 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9591 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Speed Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The speed sensor (1) is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Operation OPERATION Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. Signals from this sensor are shared with the powertrain control module. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9594 Transmission Speed Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9595 Transmission Speed Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION INPUT AND OUTPUT SPEED SENSORS The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate DC square wave signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the "teeth" of the gear pass by the sensor coil, an DC square wave is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an DC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Transmission Speed Sensor: Service and Repair 68RFE Automatic Transmission Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the transmission case. Installation INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9598 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. Installation INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9599 Transmission Speed Sensor: Service and Repair AS68RC Automatic Transmission Output Speed Sensor OUTPUT SPEED SENSOR OUTPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor. 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. Input Speed Sensor INPUT SPEED SENSOR INPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9600 3. Remove the wiring connector from the input speed sensor. 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. Output Speed Sensor OUTPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. OUTPUT SPEED SENSOR 1. Lubricate the output speed sensor O-ring with MOPAR(R) AS68RC ATF. 2. Install the output speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the wiring connector onto the output speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC ATF as necessary. Input Speed Sensor INPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9601 INPUT SPEED SENSOR 1. Lubricate the output speed sensor O-ring with MOPAR(R) AS68RC ATF. 2. Install the input speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the electrical wiring connector onto the input speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC as necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Component ID: 431 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 TCC TEMPERATURE SIGNAL T819 20YL/VT 2 TEMPERATURE SENSOR GROUND T820 20YL/WT Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 9605 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 9606 Transmission Temperature Sensor/Switch: Diagrams Component ID: 431 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 TCC TEMPERATURE SIGNAL T819 20YL/VT 2 TEMPERATURE SENSOR GROUND T820 20YL/WT Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 9607 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Valve Body: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The valve body consists of a cast aluminum valve body, a separator plate, and transfer plate. The valve body contains valves and check balls that control fluid delivery to the torque converter clutch, bands, and frictional clutches. The valve body contains the following components. By adjusting the spring pressure acting on the regulator valve, transmission line pressure can be adjusted. Upper Housing Control Valve Locations - Regulator valve (2) - Switch valve (3) - Regulator valve spring (4) - Kickdown valve (5) - Kickdown detent (6) - Throttle valve and spring (7) - Manual valve (8) - 1-2 Governor plug (9) - Throttle pressure plug (11) - 2-3 Governor plug (12) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9612 - Shuttle valve primary spring (13) Shuttle and Boost Valve Locations - Boost Valve (3) - Boost valve plug (4) - Shuttle valve (9) - Shuttle valve throttle plug (12) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9613 Upper Housing Shift Valve and Pressure Plug Locations - 1-2 shift valve (2) - 1-2 control valve - 2-3 shift valve - 2-3 throttle plug - Throttle pressure plug - Limit valve and spring Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9614 Lower Housing Shift Valves and Springs - 3-4 shift valve - 3-4 timing valve - 3-4 quick fill valve - 3-4 accumulator - Converter clutch lock-up valve - Converter clutch lock-up timing valve Operation OPERATION NOTE: Refer to the Hydraulic Schematics for a visual aid in determining valve location, operation and design. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9615 CHECK BALLS REGULATOR VALVE Regulator Valve in Park Position The pressure regulator valve is needed to control the hydraulic pressure within the system and reduce the amount of heat produced in the fluid. The pressure regulator valve is located in the valve body near the manual valve. The pressure regulator valve train controls the maximum pressure in the lines by metering the dumping of fluid back into the sump. Regulated pressure is referred to as "line pressure." The regulator valve has a spring on one end that pushes the valve to the left. This closes a dump (vent) that is used to lower pressure. The closing of the dump will cause the oil pressure to increase. Oil pressure on the opposite end of the valve pushes the valve to the right, opening the dump and lowering oil pressure. The result is spring pressure working against oil pressure to maintain the oil at specific pressures. With the engine running, fluid flows from the pump to the pressure regulator valve, manual valve, and the interconnected circuits. As fluid is sent through passages to the regulator valve, the pressure pushes the valve to the right against the large spring. It is also sent to the reaction areas on the left side of the throttle pressure plug and the line pressure plug. With the gear selector in the PARK position, fluid recirculates through the regulator and manual valves back to the sump. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9616 Regulator Valve in Neutral Position Meanwhile, the torque converter is filled slowly. In all other gear positions, fluid flows between two right side lands to the switch valve and torque converter. At low pump speeds, the flow is controlled by the pressure valve groove to reduce pressure to the torque converter. After the torque converter and switch valve fill with fluid, the switch valve becomes the controlling metering device for torque converter pressure. The regulator valve then begins to control the line pressure for the other transmission circuits. The balance of the fluid pressure pushing the valve to the right and the spring pressure pushing to the left determines the size of the metering passage at land #2 (land #1 being at the far right of the valve in the diagram). As fluid leaks past the land, it moves into a groove connected to the filter or sump. As the land meters the fluid to the sump, it causes the pressure to reduce and the spring decreases the size of the metering passage. When the size of the metering passage is reduced, the pressure rises again and the size of the land is increased again. Pressure is regulated by this constant balance of hydraulic and spring pressure. Regulator Valve in Drive Position The metering at land #2 establishes the line pressure throughout the transmission. It is varied according to changes in throttle position and the transmission's internal condition within a range of 57-94 psi (except in REVERSE). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9617 Regulator Valve in Reverse Position The regulated line pressure in REVERSE is held at much higher pressures than in the other gear positions: 145-280 psi. The higher pressure for REVERSE is achieved by the manual valve blocking the supply of line pressure to the reaction area left of land #4. With this pressure blocked, there is less area for pressure to act on to balance the force of the spring on the right. This allows line pressure to push the valve train to the right, reducing the amount of fluid returned to the pump's inlet, increasing line pressure. KICKDOWN VALVE Kickdown Valve - Wide Open Throttle When the throttle valve is as far over to the left as it can go, the maximum line pressure possible will enter the throttle pressure circuit. In this case, throttle pressure will equal line pressure. With the kickdown valve pushed into the bore as far as it will go, fluid initially flows through the annular Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9618 groove of the 2-3 shift valve (which will be in the direct drive position to the right). After passing the annular groove, the fluid is routed to the spring end of the 2-3 shift valve. Fluid pressure reacting on the area of land #1 overcomes governor pressure, downshifting the 2-3 shift valve into the kickdown, or second gear stage of operation. The valve is held in the kickdown position by throttle pressure routed from a seated check ball (#2). Again, if vehicle speed is low enough, throttle pressure will also push the 1-2 shift valve left to seat its governor plug, and downshift to drive breakaway. KICKDOWN LIMIT VALVE Kickdown Limit Valve - Low Speeds The purpose of the limit valve is to prevent a 3-2 downshift at higher speeds when a part-throttle downshift is not desirable. At these higher speeds only a full throttle 3-2 downshift will occur. At low road speeds the limit valve does not come into play and does not affect the downshifts. Kickdown Limit Valve - High Speeds As the vehicle's speed increases, the governor pressure also increases. The increased governor pressure acts on the reaction area of the bottom land of the limit valve overcoming the spring force trying to push the valve toward the bottom of its bore. This pushes the valve upward against the spring and bottoms the valve against the top of the housing. With the valve bottomed against the housing, the throttle pressure supplied to the valve will be closed off by the bottom land of the limit valve. When the supply of throttle pressure has been shut off, the 3-2 part throttle downshift plug becomes inoperative, because no pressure is acting on its reaction area. 1-2 SHIFT VALVE 1-2 Shift Valve - Before Shift Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9619 The 1-2 shift valve assembly, or mechanism, consists of: the 1-2 shift valve, governor plug, and a spring on the end of the valve. After the manual valve has been placed into a forward gear range, line pressure is directed to the 1-2 shift valve. As the throttle is depressed, throttle pressure is applied to the right side of the 1-2 shift valve assembly. With throttle pressure applied to the right side of the valve, there is now both spring pressure and throttle pressure acting on the valve, holding it against the governor plug. As the vehicle begins to move and build speed, governor pressure is created and is applied to the left of the valve at the governor plug. 1-2 Shift Valve - After Shift When governor pressure builds to a point where it can overcome the combined force of the spring and throttle pressure on the other side of the valve, the valve will begin to move over to the right. As the valve moves to the right, the middle land of the valve will close off the circuit supplying the throttle pressure to the right side of the valve. When the throttle pressure is closed off, the valve will move even farther to the right, allowing line pressure to enter another circuit and energize the front servo, applying the front band. The governor plug serves a dual purpose: - It allows the shift valves to move either left or right, allowing both upshifts and downshifts. - When in a manual selection position, it will be hydraulically "blocked" into position so no upshift can occur. The physical blocking of the upshift while in the manual "1" position is accomplished by the directing of line pressure between both lands of the governor plug. The line pressure reacts against the larger land of the plug, pushing the plug back against the end plate overcoming governor pressure. With the combination of the line pressure and spring pressure, the valve cannot move, preventing any upshift. 1-2 SHIFT CONTROL VALVE 1-2 Shift Control Valve It contains a valve with four lands and a spring. It is used as both a "relay" and "balanced" valve. The valve has two specific operations: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9620 - Aid in quality of the 1-2 upshift. - Aid in the quality and timing of the 3-2 kickdown ranges. When the manual valve is set to the DRIVE position and the transmission is in the first or second gear range, 1-2 shift control or "modulated throttle pressure" is supplied to the middle of the accumulator piston by the 1-2 shift control valve. During the 1-2 upshift, this pressure is used to control the kickdown servo apply pressure that is needed to apply the kickdown and accumulator pistons. Thus, the 1-2 shift point is "cushioned" and the quality is improved. During a WOT kickdown, kickdown pressure is applied between the kickdown valve and the 1-2 shift control valve. This additional pressure is directed to the 1-2 shift control's spring cavity, adding to the spring load on the valve. The result of this increased "modulated" throttle pressure is a firmer WOT upshift. 2-3 SHIFT VALVE 2-3 Shift Valve - Before Shift The 2-3 shift valve mechanism consists of the 2-3 shift valve, governor plug and spring, and a throttle plug. After the 1-2 shift valve has completed its operation and applied the front band, line pressure is directed to the 2-3 shift valve through the connecting passages from the 1-2 shift valve. The line pressure will then dead-end at land #2 until the 2-3 valve is ready to make its shift. Now that the vehicle is in motion and under acceleration, there is throttle pressure being applied to the spring side of the valve and between lands #3 and #4. 2-3 Shift Valve - After Shift As vehicle speed increases, governor pressure increases proportionately, until it becomes great enough to overcome the combined throttle and spring pressure on the right side of the valve. Since the throttle pressure end of the 2-3 shift valve is larger in diameter than the 1-2 shift valve, the 2-3 shift will always happen at a greater speed than the 1-2 shift. When this happens, the governor plug is forced against the shift valve moving it to the right. The shift valve causes land #4 to close the passage supplying throttle pressure to the 2-3 shift valve. Without throttle pressure present in the circuit now, the Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9621 governor plug will push the valve over far enough to bottom the valve in its bore. This allows land #2 to direct line pressure to the front clutch. After the shift, line pressure is directed to the release side of the kickdown servo. This releases the front band and applies the front clutch, shifting into third gear or direct drive. The rear clutch remains applied, as it has been in the other gears. During a manual "1" or manual "2" gear selection, line pressure is sent between the two lands of the 2-3 governor plug. This line pressure at the governor plug locks the shift valve into the second gear position, preventing an upshift into direct drive. The theory for the blocking of the valve is the same as that of the 1-2 shift valve. If the manual "2" or manual "1" gear position is selected from the drive position, the PCM will control the timing of the downshift by targeting for a high governor pressure. When a safe vehicle speed is reached, the PCM will switch to its normal control governor curve and the downshift will occur. 3-4 SHIFT VALVE 3-4 Shift Valve Before Shift The PCM energizes the overdrive solenoid during the 3-4 upshift. This causes the solenoid check ball to close the vent port allowing line pressure from the 2-3 shift valve to act directly on the 3-4 upshift valve. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9622 3-4 Shift Valve After Shift Line pressure on the 3-4 shift valve overcomes valve spring pressure moving the valve to the upshift position. This action exposes the feed passages to the 3-4 timing valve, 3-4 quick fill valve, 3-4 accumulator, and ultimately to the overdrive piston. 3-4 TIMING VALVE 3-4 Shift Valve After Shift The 3-4 timing valve is moved by line pressure coming through the 3-4 shift valve or the converter clutch valve. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9623 3-4 Shift Valve Before Shift After the shift, the timing valve holds the 2-3 shift valve in an upshift position. The purpose is to prevent the 2-3 valve from downshifting while either the overdrive clutch or converter clutch is applied. 3-4 QUICK FILL VALVE 3-4 Shift Valve Before Shift The 3-4 quick fill valve provides faster engagement of the overdrive clutch during 3-4 upshifts. The valve temporarily bypasses the clutch piston feed orifice at the start of a 3-4 upshift. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9624 3-4 Shift Valve After Shift This exposes a larger passage into the piston retainer resulting in a much faster clutch fill and apply sequence. The quick fill valve does not bypass the regular clutch feed orifice throughout the 3-4 upshift. Instead, once a predetermined pressure develops within the clutch, the valve closes the bypass. Clutch fill is then completed through the regular feed orifice. THROTTLE VALVE Throttle Valve In all gear positions, the throttle valve is being supplied with line pressure. The throttle valve meters and reduces the line pressure that now becomes throttle pressure. The throttle valve is moved by a spring and the kickdown valve, which is mechanically connected to the throttle. The larger the throttle opening, the higher the throttle pressure (to a maximum of line pressure). The smaller the throttle opening, the lower the throttle pressure (to a minimum of zero at idle). As engine speed increases, the increase in pump speed increases pump output. The increase in pressure and volume must be regulated to maintain the balance within the transmission. To do this, throttle pressure is routed to the reaction area on the right side of the throttle pressure plug (in the regulator valve). The higher engine speed and line pressure would open the vent too far and reduce line pressure too much. Throttle pressure, which increases with engine speed (throttle opening), is used to oppose the movement of the pressure valve to help control the metering passage at the vent. The throttle pressure is combined with spring pressure to reduce the force of the throttle pressure plug on the pressure valve. The larger spring at the right closes the regulator valve passage and maintains or increases line pressure. The increased line pressure works against the reaction area of the line pressure plug and the Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9625 reaction area left of land #3 simultaneously moves the regulator valve train to the right and controls the metering passage. The kickdown valve, along with the throttle valve, serve to delay upshifts until the correct vehicle speed has been reached. It also controls downshifts upon driver demand, or increased engine load. If these valves were not in place, the shift points would be at the same speed for all throttle positions. The kickdown valve is actuated by a cam connected to the throttle. This is accomplished through either a linkage or a cable. The cam forces the kickdown valve toward the throttle valve compressing the spring between them and moving the throttle valve. As the throttle valve land starts to uncover its port, line pressure is "metered" out into the circuits and viewed as throttle pressure. This increased throttle pressure is metered out into the circuits it is applied to: the 1-2 and 2-3 shift valves. When the throttle pressure is high enough, a 3-2 downshift will occur. If the vehicle speed is low enough, a 2-1 downshift will occur. SWITCH VALVE Switch Valve - Torque Converter Unlocked When the transmission is in Drive Second before the TCC application occurs, the pressure regulator valve is supplying torque converter pressure to the switch valve. The switch valve directs this pressure through the transmission input shaft, into the converter, through the converter, back out between the input shaft and the reaction shaft, and back up to the switch valve. From the switch valve, the fluid pressure is directed to the transmission cooler, and lubrication pressure returns from the cooler to lubricate different portions of the transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9626 Switch Valve - Torque Converter Locked MANUAL VALVE The manual valve is a relay valve. The purpose of the manual valve is to direct fluid to the correct circuit needed for a specific gear or driving range. The manual valve, as the name implies, is manually operated by the driver with a lever located on the side of the valve body. The valve is connected mechanically by either a cable or linkage to the gearshift mechanism. The valve is held in each of its positions by a spring-loaded roller or ball that engages the "roostercomb" of the manual valve lever. Manual Valve Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9627 Once the TCC control valve has moved to the right, line pressure is directed to the tip of the switch valve, forcing the valve to the right. The switch valve now vents oil from the front of the piston in the torque converter, and supplies line pressure to the (rear) apply side of the torque converter piston. This pressure differential causes the piston to apply against the friction material, cutting off any further flow of line pressure oil. After the switch valve is shuttled right allowing line pressure to engage the TCC, torque converter pressure is directed past the switch valve into the transmission cooler and lubrication circuits. CONVERTER CLUTCH LOCK-UP VALVE The torque converter clutch (TCC) lock-up valve controls the back (ON) side of the torque converter clutch. When the PCM energizes the TCC solenoid to engage the converter clutch piston, pressure is applied to the TCC lock-up valve which moves to the right and applies pressure to the torque converter clutch. CONVERTER CLUTCH LOCK-UP TIMING VALVE The torque converter clutch (TCC) lock-up timing valve is there to block any 4-3 downshift until the TCC is completely unlocked and the clutch is disengaged. SHUTTLE VALVE The assembly is contained in a bore in the valve body above the shift valves. When the manual valve is positioned in the Drive range, throttle pressure acts on the throttle plug of the shuttle valve to move it against a spring, increasing the spring force on the shuttle valve. During a part or full throttle 1-2 upshift, the throttle plug is bottomed by throttle pressure, holding the shuttle valve to the right against governor pressure, and opening a by-pass circuit. The shuttle valve controls the quality of the kickdown shift by restricting the rate of fluid discharge from the front clutch and servo release circuits. During a 3-2 kickdown, fluid discharges through the shuttle by-pass circuit. When the shuttle valve closes the by-pass circuit, fluid discharge is restricted and controlled for the application of the front band. During a 2-3 "lift foot" upshift, the shuttle valve by-passes the restriction to allow full fluid flow through the by-pass groove for a faster release of the band. BOOST VALVE Boost Valve Before Lock-up The boost valve provides increased fluid apply pressure to the overdrive clutch during 3-4 upshifts, and when accelerating in fourth gear. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9628 Boost Valve After Lock-up The boost valve also serves to increase line pressure during torque converter lock-up. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9629 Valve Body: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION Valve Body Components The valve body consists of a cast aluminum valve body, a separator plate, and a transfer plate. The valve body contains valves and check balls that control fluid delivery to the torque converter clutch and frictional clutches. The valve body contains the following components: - Solenoid switch valve - Manual valve - Low/reverse shuttle valve - 5 Accumulators Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9630 Check Ball Locations - 7 check balls Operation OPERATION NOTE: Refer to the Hydraulic Schematics for a visual aid in determining valve location, operation and design. SOLENOID SWITCH VALVE The Solenoid Switch Valve (SSV) controls the direction of the transmission fluid when the L/R-TCC solenoid is energized. The Solenoid Switch Valve controls line pressure from the LR-TCC solenoid. In 1st gear, the SSV will be in the downshifted position, thus directing fluid to the L/R clutch circuit. In all other gears, the solenoid switch valve will be in the upshifted position and directs the fluid into the torque converter clutch (TCC) circuit. When shifting into 1st gear, a special hydraulic sequence is performed to ensure SSV movement into the downshifted position. The L/R pressure switch is monitored to confirm SSV movement. If the movement is not confirmed (the L/R pressure switch does not close), 2nd gear is substituted for 1st. A DTC will be set after three unsuccessful attempts are made to get into 1st gear in one given key start. MANUAL VALVE The manual valve is a relay valve. The purpose of the manual valve is to direct fluid to the correct circuit needed for a specific gear or driving range. The manual valve, as the name implies, is manually operated by the driver with a lever located on the top of the valve body. The valve is connected mechanically to the gearshift mechanism. The valve is held in each of its positions by a roller detent spring (2) that engages the roostercomb of the TRS selector plate (1). LOW/REVERSE SWITCH VALVE The low/reverse switch valve allows the low/reverse clutch to be operated by either the LR/CC solenoid or the MS solenoid. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9631 Valve Body: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION The valve body consists of a two piece aluminum valve body. Extensive electronic control effected by a microcomputer (the automatic transmission electronic control unit) over the hydraulic circuitry enables precise control over gearshifts. The valve body contains valves and pressure sensors that control fluid delivery to the torque converter clutch, forward clutches, and brake clutches. UPPER VALVE BODY UPPER VALVE BODY The upper valve body contains the following components: - 1 = Combined Drain - 2 = Gain change solenoid valve - 3 = Manual valve - 4 = Modulator valve - 5 = Shift solenoid valve No. 3 - 6 = Shift solenoid valve No. 2 - 7 = Shift valve No. 1 LOWER VALVE BODY Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9632 LOWER VALVE BODY The lower valve body contains the following components: - 1 = Control valve No. 3 - 2 = Shift solenoid valve No. 4 - 3 = Lockup control valve - 4 = Control valve No. 1 - 5 = Control valve No. 2 SWITCHES AND SOLENOIDS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9633 VALVE BODY OIL SWITCH HARNESS There are eight pressure switches and one ATF temperature switch used to inform the Transmission Control Module (TCM) when there is pressure in various hydraulic circuits. Six of them are located on the bottom of the valve body. The remainder are located on the top of the valve body. SWITCHES AND SOLENOIDS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9634 VALVE BODY SOLENOID HARNESS Eight solenoids are used to control various shift functions in the transmission. Four are located on the top of the valve body (3, 4) and the remainder are located on the bottom of the valve body. Operation OPERATION LOWER VALVE BODY Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9635 LOWER VALVE BODY UPPER VALVE BODY Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9636 UPPER VALVE BODY Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9637 SWITCHES AND SOLENOIDS VALVE BODY OIL SWITCH HARNESS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9638 SWITCHES AND SOLENOIDS VALVE BODY SOLENOID HARNESS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9639 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > Page 9640 Valve Body: Adjustments ADJUSTMENTS - VALVE BODY CONTROL PRESSURE ADJUSTMENTS There are two control pressure adjustments on the valve body; - Line Pressure - Throttle Pressure Line and throttle pressures are interdependent because each affects shift quality and timing. As a result, both adjustments must be performed properly and in the correct sequence. Adjust line pressure first and throttle pressure last. LINE PRESSURE ADJUSTMENT 1. Measure distance (2) from the valve body to the inner edge of the adjusting screw with an accurate steel scale. Distance should be 33.4 mm (1-5/16 in.). If adjustment is required, turn the adjusting screw in, or out, to obtain required distance setting. NOTE: The 33.4 mm (1-5/16 in.) setting is an approximate setting. Manufacturing tolerances may make it necessary to vary from this dimension to obtain desired pressure. One complete turn of the adjusting screw changes line pressure approximately 1-2/3 psi (9 kPa). Turning the adjusting screw counterclockwise increases pressure while turning the screw clockwise decreases pressure. THROTTLE PRESSURE ADJUSTMENT 2. Insert Throttle Setting Gauge Tool C-3763 between the throttle lever cam and the kickdown valve stem (2). 3. Push the gauge tool inward to compress the kickdown valve against the spring and bottom the throttle valve. 4. Maintain pressure against kickdown valve spring. Turn throttle lever stop screw until the screw head touches throttle lever tang and the throttle lever cam touches gauge tool. NOTE: The kickdown valve spring must be fully compressed and the kickdown valve completely bottomed to obtain correct adjustment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Valve Body: Service and Repair 68RFE Automatic Transmission Cleaning CLEANING Clean the valve housings, valves, plugs, springs, transfer plate and separator plate with a standard parts cleaning solution only. Do not use gasoline, kerosene, or any type of caustic solution. Do not immerse any of the electrical components in cleaning solution. Clean the electrical components by wiping them off with dry shop towels only. Dry all except the electrical parts with compressed air. Make sure all passages are clean and free from obstructions. Do not use rags or shop towels to dry or wipe off valve body components. Lint from these materials can stick to valve body parts, interfere with valve operation, and clog filters and fluid passages. Inspection INSPECTION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9643 Valve Body Components NOTE: Only the INNER accumulator seal ring actually seals the pressure in the bore. The outer seal ring only serves to guide the piston in the bore. Gouges which do not extend past the inner seal ring (and have no raised edges, which could damage the guide ring) are acceptable. The machined accumulator bores often have a tiger-striped appearance. This is NORMAL and does NOT require replacement, as long as the bores are smooth in the inner seal ring area. Inspect all of the valve body mating surfaces for scratches, nicks, burrs, or distortion. Use a straightedge to check surface flatness. Minor scratches may be removed with crocus cloth using only very light pressure. Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth. Position the crocus cloth on a surface plate, sheet of plate glass or equally flat surface. If distortion is severe or any surfaces are heavily scored, the valve body will have to be replaced. Inspect the valves and plugs for scratches, burrs, nicks, or scores. Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands. Maintaining sharpness of these edges is vitally important. The edges prevent foreign matter from lodging between the valves and plugs and the bore. Inspect all the valve and plug bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The springs must be free of distortion, warpage or broken coils. Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the valves and plugs should drop freely into the bores. Valve body bores do not normally change dimensionally with use. If the valve body functioned correctly when new, it should continue to operate properly after cleaning and inspection. It should not be necessary to replace a valve body assembly unless it is damaged in handling. Inspect all the accumulator bores in the valve body as well as the accumulator piston seal rings, and replace if cut or damaged. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the accumulator springs. The springs must be free of distortion, warpage or broken coils. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9644 Valve Body Seals Inspect all the fluid seals on the valve body. Replace any seals that are cracked, distorted, or damaged in any way. These seals pass fluid pressure directly to the clutches. Any pressure leak at these points, may cause transmission performance problems. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9645 Valve Body: Service and Repair 48RE Automatic Transmission Cleaning CLEANING Clean the valve housings, valves, plugs, springs, and separator plates with a standard parts cleaning solution only. Do not use gasoline, kerosene, or any type of caustic solution. Do not immerse any of the electrical components in cleaning solution. Clean the governor solenoid and sensor and the dual solenoid and harness assembly by wiping them off with dry shop towels only. Dry all except the electrical parts with compressed air. Make sure all passages are clean and free from obstructions. Do not use rags or shop towels to dry or wipe off valve body components. Lint from these materials can stick to valve body parts, interfere with valve operation, and clog filters and fluid passages. Wipe the governor pressure sensor and solenoid valve with dry, lint free shop towels only. The O-rings on the sensor and solenoid valve are the only serviceable components. Be sure the vent ports in the solenoid valve are open and not blocked by dirt or debris. Replace the valve and/or sensor only when DRB scan tool diagnosis indicates this is necessary. Or, if either part has sustained physical damage (dented, deformed, broken, etc.). CAUTION: Do not turn the small screw at the end of the solenoid valve for any reason. Turning the screw in either direction will ruin solenoid calibration and result in solenoid failure. In addition, the filter on the solenoid valve is NOT serviceable. Do not try to remove the filter as this will damage the valve housing. Inspection INSPECTION Inspect the throttle and manual valve levers and shafts. Do not attempt to straighten a bent shaft or correct a loose lever. Replace these components if worn, bent, loose or damaged in any way. Inspect all of the valve body mating surfaces for scratches, nicks, burrs, or distortion. Use a straightedge to check surface flatness. Minor scratches may be removed with crocus cloth using only very light pressure. Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth. Position the crocus cloth on a surface plate, sheet of plate glass or equally flat surface. If distortion is severe or any surfaces are heavily scored, the valve body will have to be replaced. CAUTION: Many of the valves and plugs, such as the throttle valve, shuttle valve plug, 1-2 shift valve and 1-2 governor plug, are made of coated aluminum. Aluminum components are identified by the dark color of the special coating applied to the surface (or by testing with a magnet). Do not sand aluminum valves or plugs under any circumstances. This practice could damage the special coating causing the valves/plugs to stick and bind. Inspect the valves and plugs for scratches, burrs, nicks, or scores. Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands. Maintaining sharpness of these edges is vitally important. The edges prevent foreign matter from lodging between the valves and plugs and the bore. Inspect all the valve and plug bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The springs must be free of distortion, warpage or broken coils. Check the two separator plates for distortion or damage of any kind. Inspect the upper housing, lower housing, 3-4 accumulator housing, and transfer plate carefully. Be sure all fluid passages are clean and clear. Check condition of the upper housing and transfer plate check balls as well. The check balls and ball seats must not be worn or damaged. Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the valves and plugs should drop freely into the bores. Valve body bores do not change dimensionally with use. If the valve body functioned correctly when new, it will continue to operate properly after cleaning and inspection. It should not be necessary to replace a valve body assembly unless it is damaged in handling. The only serviceable valve body components are listed below. The remaining valve body components are serviced only as part of a complete valve body assembly. Serviceable parts are: - dual solenoid and harness assembly - solenoid gasket Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9646 - solenoid case connector O-rings and shoulder bolt - switch valve and spring - pressure adjusting screw and bracket assembly - throttle lever - manual lever and shaft seal - throttle lever shaft seal, washer, and E-clip - fluid filter and screws - detent ball and spring - valve body screws - governor pressure solenoid - governor pressure sensor and retaining clip - park lock rod and E-clip Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9647 Valve Body: Service and Repair AS68RC Automatic Transmission Cleaning CLEANING UPPER VALVE BODY Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9648 LOWER VALVE BODY Clean the valve housings, valves, plugs, springs, and separator plates with a standard parts cleaning solution only. Do not use gasoline, kerosene, or any type of caustic solution. Do not immerse any of the electrical components in cleaning solution. Clean the electrical components by wiping them off with dry shop towels only. Dry all except the electrical parts with compressed air. Make sure all passages are clean and free from obstructions. Do not use rags or shop towels to dry or wipe off valve body components. Lint from these materials can stick to valve body parts, interfere with valve operation, and clog filters and fluid passages. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9649 SOLENOID FILTER SCREEN 1 - SOLENOID FILTER SCREEN Clean the solenoid filter screen (1), (if equipped). Inspection INSPECTION Inspect all of the valve body mating surfaces for scratches, nicks, burrs, or distortion. Use a straightedge to check surface flatness. Minor scratches may be removed with crocus cloth using only very light pressure. Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth. Position the crocus cloth on a surface plate, sheet of plate glass or equally flat surface. If distortion is severe or any surfaces are heavily scored, the valve body will have to be replaced. Inspect the valves and plugs for scratches, burrs, nicks, or scores. Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands. Maintaining sharpness of these edges is vitally important. The edges prevent foreign matter from lodging between the valves and plugs and the bore. Inspect all the valve and plug bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The springs must be free of distortion, warpage or broken coils. Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the valves and plugs should drop freely into the bores. Valve body bores do not change dimensionally with use. If the valve body functioned correctly when new, it will continue to operate properly after cleaning and inspection. It should not be necessary to replace a valve body assembly unless it is damaged in handling. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9650 SOLENOID FILTER SCREEN 1 - SOLENOID FILTER SCREEN Inspect all solenoid filter screens (1). Inspect all the fluid seals in the transmission case. Replace any seals that are cracked, distorted, or damaged in any way. These seals pass fluid pressure directly to the clutches. Any pressure leak at these points, may cause transmission performance problems. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch Disc: > 06-001-07 > Feb > 07 > M/T - Difficult Gear Engagement Clutch Disc: Customer Interest M/T - Difficult Gear Engagement NUMBER: 06-001-07 GROUP: Clutch DATE: February 03, 2007 SUBJECT: Clutch System May Over-Adjust Causing Difficulty Engaging Transmission Gear OVERVIEW: This bulletin involves replacement of the clutch system flywheel, pressure plate, and disc. MODELS: 2007 (DHID1IDC) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 5.9L or 6.7L Cummins turbo-diesel engine and the G56 manual transmission (sales code ETH, ETJ, and DEG respectively), and built on or before November 09, 2006 (MDH 1109XX). SYMPTOM/CONDITION: The customer may experience difficulty attempting to engage a manual transmission gear. This may be due to the self-adjusting mechanism in the clutch system. The self-adjusting clutch mechanism may over-adjust (forward adjust). This condition most often will occur within the first 1,000 miles of vehicle operation. DIAGNOSIS: 1. Inspect the clutch hydraulic system for leaks and or low fluid. 2. Is there a clutch system hydraulic leak and/or is the hydraulic fluid level low? a. If YES >> then repair the clutch hydraulic system. Proceed to the next step. b. If NO »> then proceed to the next step. 3. Evaluate the shift efforts of 1st gear when the engine is off and when the engine is running. a. With the engine off and the clutch pedal fully depressed (pushed down) attempt to shift into 1st gear. b. With the transmission in neutral, parking brake firmly set, start the engine and allow to idle. c. With the engine running, service brake fully applied, and the clutch pedal fully depressed (pushed down) attempt to shift into 1st gear. 4. When attempting to engage 1st gear, is the shift effort substantially higher (more difficult or unable to engage 1st gear) when the engine is running, than when the engine is off? a. If YES >> then perform the Repair Procedure b. If NO >> then proceed to the next step. 5. Evaluate the shift efforts of Reverse gear when the engine is off and when the engine is running. a. With the engine off and the clutch pedal fully depressed (pushed down) attempt to shift into Reverse gear. b. With the transmission in neutral, parking brake firmly set, start the engine and allow to idle. C. With the engine running, service brake fully applied, and the clutch pedal fully depressed (pushed down) attempt to shift into Reverse gear. 6. When attempting to engage Reverse gear, is the shift effort substantially higher (more difficult or unable to engage Reverse gear) when the engine is running, than when the engine is off? a. If YES »> then perform the Repair Procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch Disc: > 06-001-07 > Feb > 07 > M/T - Difficult Gear Engagement > Page 9660 b. If NO »> then this Bulletin does not apply. Further diagnosis is required. PARTS REQUIRED: REPAIR PROCEDURE: NOTE:When the clutch pressure plate over-adjusts, the plate diaphragm fingers appear to be flat (collapsed) and marks on the clutch disc will be present due to contact with the collapsed plate diaphragm fingers. 1. Replace the dual mass flywheel, pressure plate, clutch disc, and plate attaching bolts. Refer to TechCONNECT for detailed service repair procedures. From TechCONNECT select: the "Service Info" tab and enter vehicle information (year, model, and engine). Select: 6 - Clutch > Flywheel and Disc - Clutch > Removal, Installation, and Adjustments. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Disc: > 06-001-07 > Feb > 07 > M/T - Difficult Gear Engagement Clutch Disc: All Technical Service Bulletins M/T - Difficult Gear Engagement NUMBER: 06-001-07 GROUP: Clutch DATE: February 03, 2007 SUBJECT: Clutch System May Over-Adjust Causing Difficulty Engaging Transmission Gear OVERVIEW: This bulletin involves replacement of the clutch system flywheel, pressure plate, and disc. MODELS: 2007 (DHID1IDC) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 5.9L or 6.7L Cummins turbo-diesel engine and the G56 manual transmission (sales code ETH, ETJ, and DEG respectively), and built on or before November 09, 2006 (MDH 1109XX). SYMPTOM/CONDITION: The customer may experience difficulty attempting to engage a manual transmission gear. This may be due to the self-adjusting mechanism in the clutch system. The self-adjusting clutch mechanism may over-adjust (forward adjust). This condition most often will occur within the first 1,000 miles of vehicle operation. DIAGNOSIS: 1. Inspect the clutch hydraulic system for leaks and or low fluid. 2. Is there a clutch system hydraulic leak and/or is the hydraulic fluid level low? a. If YES >> then repair the clutch hydraulic system. Proceed to the next step. b. If NO »> then proceed to the next step. 3. Evaluate the shift efforts of 1st gear when the engine is off and when the engine is running. a. With the engine off and the clutch pedal fully depressed (pushed down) attempt to shift into 1st gear. b. With the transmission in neutral, parking brake firmly set, start the engine and allow to idle. c. With the engine running, service brake fully applied, and the clutch pedal fully depressed (pushed down) attempt to shift into 1st gear. 4. When attempting to engage 1st gear, is the shift effort substantially higher (more difficult or unable to engage 1st gear) when the engine is running, than when the engine is off? a. If YES >> then perform the Repair Procedure b. If NO >> then proceed to the next step. 5. Evaluate the shift efforts of Reverse gear when the engine is off and when the engine is running. a. With the engine off and the clutch pedal fully depressed (pushed down) attempt to shift into Reverse gear. b. With the transmission in neutral, parking brake firmly set, start the engine and allow to idle. C. With the engine running, service brake fully applied, and the clutch pedal fully depressed (pushed down) attempt to shift into Reverse gear. 6. When attempting to engage Reverse gear, is the shift effort substantially higher (more difficult or unable to engage Reverse gear) when the engine is running, than when the engine is off? a. If YES »> then perform the Repair Procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Disc: > 06-001-07 > Feb > 07 > M/T - Difficult Gear Engagement > Page 9666 b. If NO »> then this Bulletin does not apply. Further diagnosis is required. PARTS REQUIRED: REPAIR PROCEDURE: NOTE:When the clutch pressure plate over-adjusts, the plate diaphragm fingers appear to be flat (collapsed) and marks on the clutch disc will be present due to contact with the collapsed plate diaphragm fingers. 1. Replace the dual mass flywheel, pressure plate, clutch disc, and plate attaching bolts. Refer to TechCONNECT for detailed service repair procedures. From TechCONNECT select: the "Service Info" tab and enter vehicle information (year, model, and engine). Select: 6 - Clutch > Flywheel and Disc - Clutch > Removal, Installation, and Adjustments. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Technical Service Bulletins > Page 9667 Clutch Disc: Adjustments PRESSURE PLATE DIAPHRAGM SPRINGS NOTE:Perform the following procedure, when replacing only the clutch disc on Diesel vehicles with Dual Mass Flywheel and self- adjusting pressure plate. The pressure plate must be reset before installing a new disc. 1. Support pressure plate flange with press blocks (3) on a press. 2. Center press ram (2) on the pressure plate diaphragm spring fingers (1). 3. Compress the diaphragm spring fingers (1), until tension is released from the stepped adjusting ring. 4. Place two screwdrivers against two of the three stepped adjusting ring (1) tension spring stops, just ahead of the adjusting ring tension springs on the pressure plate (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Technical Service Bulletins > Page 9668 5. Rotate stepped adjusting ring (1) on the pressure plate (2) counterclockwise until the coil springs are fully compressed. Then hold adjusting ring while releasing the press pressure. 6. Remove the screwdrivers. The pressure plate is know adjusted for a new clutch disc. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Clutch Disc - Removal Clutch Disc: Service and Repair Clutch Disc - Removal REMOVAL 1. Support engine with wood block and adjustable jack stand, to prevent strain on engine mounts. 2. Remove transmission and transfer case, if equipped. 3. If pressure plate (3) will be reused, mark (2) the position on flywheel (1) with paint or scriber. Also note location marks on the pressure next to the bolt holes. The mark will be a L or a circle with an X in it. 4. Insert clutch alignment tool (3) through pressure plate (2) and into pilot bushing, to hold disc in place while removing bolts. 5. Loosen pressure plate bolts evenly, a few threads at a time and in a diagonal pattern to prevent warping the plate. 6. Remove bolts completely and remove pressure plate, disc and alignment tool. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Clutch Disc - Removal > Page 9671 Clutch Disc: Service and Repair Clutch Disc - Installation INSTALLATION CAUTION: Before installing a clutch disc on the Diesel engine with Dual Mass Flywheel and self-adjusting pressure plate, the pressure plate must be reset. Failure to reset the pressure will result in damage to the clutch disc. 1. Check runout and free operation of new clutch disc. 2. Lubricate crankshaft pilot bearing with a NLGI - 2 rated grease. 3. Install clutch alignment tool in clutch disc hub with the raised side of hub is facing away from the flywheel. NOTE: Flywheel side is imprinted on the disc face. 4. Install alignment tool (3) in pilot bearing and position disc on the flywheel (1). 5. Position pressure plate over disc (2) and onto the flywheel. NOTE: Over the wear life of a clutch disc the pressure plate will loose some of it's clamp load. It is recommended when replacing a worn clutch, the pressure plate is replaced at the same time. 6. Align and hold pressure plate in position and install bolts finger tight. 7. Tighten bolts evenly and a few threads at a time in a diagonal pattern. CAUTION: Bolts must be tightened evenly and to specified torque to avoid warping pressure plate cover. 8. Tighten pressure plate bolts to: - V6 & V8 Engines - 50 Nm (37 ft. lbs.) - Diesel Engines - 30 Nm (22 ft. lbs.) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Clutch Disc - Removal > Page 9672 9. Remove release lever (3) and release bearing from clutch housing (1). Apply Mopar(R) high temperature bearing grease to bore (4) of release bearing, release lever (5) contact surfaces and release lever pivot stud (2). 10. Apply light coat of Mopar(R) high temperature bearing grease to splines (3) of transmission input shaft (1) and to release bearing slide surface of the transmission front bearing retainer (2). CAUTION: Do not over lubricate shaft splines. This can result in grease contamination of the disc. 11. Wipe pilot bearing surface clean. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Clutch Disc - Removal > Page 9673 12. Install release lever and bearing in clutch housing. Verify spring clips (2) that retain lever on pivot ball (4) and release bearing (3) are installed properly. NOTE: If release lever is installed correctly, the lever part number will be toward the bottom of the transmission and right side up. There is also a stamped "I" in the lever which goes to the pivot ball side of the transmission. 13. Install transmission and transfer case if equipped. 14. Check fluid level in clutch master cylinder and depress clutch pedal several time. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Clutch Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 9679 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Removal Clutch Master Cylinder: Service and Repair Removal REMOVAL CAUTION: The hydraulic linkage has a quick disconnect at the slave cylinder. This fitting should never be disconnected or tampered with. Once the hydraulic line is connected to the slave cylinder, it should never be disconnected. 1. Raise and support vehicle. 2. Remove heat shield over hydraulic line. 3. Remove slave cylinder (2) nuts (1) on clutch housing. 4. Remove slave cylinder from clutch housing. 5. Remove plastic clip securing the hydraulic line to the dash panel from the lower dash panel flange. 6. Remove plastic clip securing hydraulic line to the dash panel from the upper dash panel stud. 7. Lower vehicle. 8. Disconnect clutch pedal interlock switch connector (2). 9. Remove clutch master cylinder (1) rod pin (3). 10. Ensure cap on clutch cylinder reservoir is tight. 11. Remove clutch master cylinder nuts holding cylinder to the dash panel. 12. Remove clutch cylinders, reservoir and connecting lines from vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Removal > Page 9684 Clutch Master Cylinder: Service and Repair Installation INSTALLATION 1. Position cylinders and connecting line in vehicle engine compartment. Position clutch hydraulic line against the dash panel and behind all engine hoses and wiring. 2. Apply a light coating of grease to the inside diameter of the master cylinder push rod eye. 3. Install clutch master cylinder (1) on dash panel and tighten clutch master cylinder nuts to 28 Nm (21 ft. lbs.). 4. Install clutch master cylinder push rod pin (3). 5. Connect clutch pedal position interlock switch connector (2). 6. Install plastic clip securing hydraulic line to the dash panel into the lower dash panel flange. 7. Install plastic clip securing hydraulic line to the dash panel onto the upper dash panel stud. 8. Raise vehicle. 9. Install slave cylinder (2) and verify cylinder rod is properly seated in release lever. 10. Install and tighten slave cylinder nuts (1) to 23 Nm (17 ft. lbs.). 11. If new clutch linkage is being installed, connect the clutch hydraulic line to the clutch slave cylinder. CAUTION: Once the clutch hydraulic line is connected to the slave cylinder, it should never be disconnected. 12. Install heat shield over hydraulic line. 13. Operate linkage several times to verify proper operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Removal Clutch Slave Cylinder: Service and Repair Removal REMOVAL CAUTION: The hydraulic linkage has a quick disconnect at the slave cylinder. This fitting should never be disconnected or tampered with. Once the hydraulic line is connected to the slave cylinder, it should never be disconnected. 1. Raise and support vehicle. 2. Remove heat shield over hydraulic line. 3. Remove slave cylinder (2) nuts (1) on clutch housing. 4. Remove slave cylinder from clutch housing. 5. Remove plastic clip securing the hydraulic line to the dash panel from the lower dash panel flange. 6. Remove plastic clip securing hydraulic line to the dash panel from the upper dash panel stud. 7. Lower vehicle. 8. Disconnect clutch pedal interlock switch connector (2). 9. Remove clutch master cylinder (1) rod pin (3). 10. Ensure cap on clutch cylinder reservoir is tight. 11. Remove clutch master cylinder nuts holding cylinder to the dash panel. 12. Remove clutch cylinders, reservoir and connecting lines from vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Removal > Page 9689 Clutch Slave Cylinder: Service and Repair Installation INSTALLATION 1. Position cylinders and connecting line in vehicle engine compartment. Position clutch hydraulic line against the dash panel and behind all engine hoses and wiring. 2. Apply a light coating of grease to the inside diameter of the master cylinder push rod eye. 3. Install clutch master cylinder (1) on dash panel and tighten clutch master cylinder nuts to 28 Nm (21 ft. lbs.). 4. Install clutch master cylinder push rod pin (3). 5. Connect clutch pedal position interlock switch connector (2). 6. Install plastic clip securing hydraulic line to the dash panel into the lower dash panel flange. 7. Install plastic clip securing hydraulic line to the dash panel onto the upper dash panel stud. 8. Raise vehicle. 9. Install slave cylinder (2) and verify cylinder rod is properly seated in release lever. 10. Install and tighten slave cylinder nuts (1) to 23 Nm (17 ft. lbs.). 11. If new clutch linkage is being installed, connect the clutch hydraulic line to the clutch slave cylinder. CAUTION: Once the clutch hydraulic line is connected to the slave cylinder, it should never be disconnected. 12. Install heat shield over hydraulic line. 13. Operate linkage several times to verify proper operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Service and Repair > Removal Hydraulic Hose: Service and Repair Removal REMOVAL CAUTION: The hydraulic linkage has a quick disconnect at the slave cylinder. This fitting should never be disconnected or tampered with. Once the hydraulic line is connected to the slave cylinder, it should never be disconnected. 1. Raise and support vehicle. 2. Remove heat shield over hydraulic line. 3. Remove slave cylinder (2) nuts (1) on clutch housing. 4. Remove slave cylinder from clutch housing. 5. Remove plastic clip securing the hydraulic line to the dash panel from the lower dash panel flange. 6. Remove plastic clip securing hydraulic line to the dash panel from the upper dash panel stud. 7. Lower vehicle. 8. Disconnect clutch pedal interlock switch connector (2). 9. Remove clutch master cylinder (1) rod pin (3). 10. Ensure cap on clutch cylinder reservoir is tight. 11. Remove clutch master cylinder nuts holding cylinder to the dash panel. 12. Remove clutch cylinders, reservoir and connecting lines from vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Service and Repair > Removal > Page 9694 Hydraulic Hose: Service and Repair Installation INSTALLATION 1. Position cylinders and connecting line in vehicle engine compartment. Position clutch hydraulic line against the dash panel and behind all engine hoses and wiring. 2. Apply a light coating of grease to the inside diameter of the master cylinder push rod eye. 3. Install clutch master cylinder (1) on dash panel and tighten clutch master cylinder nuts to 28 Nm (21 ft. lbs.). 4. Install clutch master cylinder push rod pin (3). 5. Connect clutch pedal position interlock switch connector (2). 6. Install plastic clip securing hydraulic line to the dash panel into the lower dash panel flange. 7. Install plastic clip securing hydraulic line to the dash panel onto the upper dash panel stud. 8. Raise vehicle. 9. Install slave cylinder (2) and verify cylinder rod is properly seated in release lever. 10. Install and tighten slave cylinder nuts (1) to 23 Nm (17 ft. lbs.). 11. If new clutch linkage is being installed, connect the clutch hydraulic line to the clutch slave cylinder. CAUTION: Once the clutch hydraulic line is connected to the slave cylinder, it should never be disconnected. 12. Install heat shield over hydraulic line. 13. Operate linkage several times to verify proper operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection SWITCH-CLUTCH PEDAL POSITION 1. Disconnect switch 2-wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed - Continuity - Pedal Released - No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Service and Repair > Removal Clutch Release Bearing: Service and Repair Removal REMOVAL 1. Remove transmission and transfer case, if equipped. 2. Remove spring clip (6). 3. Disconnect release bearing (4) from release lever (3) and remove bearing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Service and Repair > Removal > Page 9702 Clutch Release Bearing: Service and Repair Installation INSTALLATION 1. Inspect bearing slide surface on transmission front bearing retainer. Replace retainer if slide surface is scored, worn, or cracked. 2. Inspect release lever (2) and pivot stud (1). Verify stud is secure and in good condition and lever is not distorted or worn. Replace fork spring clips if bent or damaged. 3. Lubricate input shaft splines, bearing retainer slide surface, pivot stud (1) and release lever pivot surface with Mopar(R) high temperature bearing grease. 4. Install release fork and release bearing. Verify fork and bearing are properly secured by spring clips and release lever is installed properly. Rear side of release lever has one end with a raised area, which goes toward the slave cylinder side of the transmission. 5. Install transmission and transfer case. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Fork, M/T > Component Information > Service and Repair > Removal Clutch Release Fork: Service and Repair Removal REMOVAL 1. Remove transmission and transfer case, if equipped. 2. Remove spring clip (6). 3. Disconnect release bearing (4) from release lever (3) and remove bearing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Fork, M/T > Component Information > Service and Repair > Removal > Page 9707 Clutch Release Fork: Service and Repair Installation INSTALLATION 1. Inspect bearing slide surface on transmission front bearing retainer. Replace retainer if slide surface is scored, worn, or cracked. 2. Inspect release lever (2) and pivot stud (1). Verify stud is secure and in good condition and lever is not distorted or worn. Replace fork spring clips if bent or damaged. 3. Lubricate input shaft splines, bearing retainer slide surface, pivot stud (1) and release lever pivot surface with Mopar(R) high temperature bearing grease. 4. Install release fork and release bearing. Verify fork and bearing are properly secured by spring clips and release lever is installed properly. Rear side of release lever has one end with a raised area, which goes toward the slave cylinder side of the transmission. 5. Install transmission and transfer case. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair > Removal Pilot Bearing: Service and Repair Removal REMOVAL 1. Remove transmission assembly from the vehicle. 2. Remove pressure plate (2) and clutch disc. 3. Remove pilot bearing with an internal puller and slide hammer to remove. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair > Removal > Page 9712 Pilot Bearing: Service and Repair Installation INSTALLATION 1. Clean bearing bore with solvent and wipe dry with shop towel. 2. Install new bearing (1) with clutch alignment tool (2) and letter side of the bearing (3) facing the transmission. Bearing should be flush with edge of bearing bore. CAUTION: Do not allow bearing to become cocked and do not recess bearing. 3. Install clutch disc, pressure plate and transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Technical Service Bulletins > Customer Interest for Pressure Plate: > 06-001-07 > Feb > 07 > M/T - Difficult Gear Engagement Pressure Plate: Customer Interest M/T - Difficult Gear Engagement NUMBER: 06-001-07 GROUP: Clutch DATE: February 03, 2007 SUBJECT: Clutch System May Over-Adjust Causing Difficulty Engaging Transmission Gear OVERVIEW: This bulletin involves replacement of the clutch system flywheel, pressure plate, and disc. MODELS: 2007 (DHID1IDC) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 5.9L or 6.7L Cummins turbo-diesel engine and the G56 manual transmission (sales code ETH, ETJ, and DEG respectively), and built on or before November 09, 2006 (MDH 1109XX). SYMPTOM/CONDITION: The customer may experience difficulty attempting to engage a manual transmission gear. This may be due to the self-adjusting mechanism in the clutch system. The self-adjusting clutch mechanism may over-adjust (forward adjust). This condition most often will occur within the first 1,000 miles of vehicle operation. DIAGNOSIS: 1. Inspect the clutch hydraulic system for leaks and or low fluid. 2. Is there a clutch system hydraulic leak and/or is the hydraulic fluid level low? a. If YES >> then repair the clutch hydraulic system. Proceed to the next step. b. If NO »> then proceed to the next step. 3. Evaluate the shift efforts of 1st gear when the engine is off and when the engine is running. a. With the engine off and the clutch pedal fully depressed (pushed down) attempt to shift into 1st gear. b. With the transmission in neutral, parking brake firmly set, start the engine and allow to idle. c. With the engine running, service brake fully applied, and the clutch pedal fully depressed (pushed down) attempt to shift into 1st gear. 4. When attempting to engage 1st gear, is the shift effort substantially higher (more difficult or unable to engage 1st gear) when the engine is running, than when the engine is off? a. If YES >> then perform the Repair Procedure b. If NO >> then proceed to the next step. 5. Evaluate the shift efforts of Reverse gear when the engine is off and when the engine is running. a. With the engine off and the clutch pedal fully depressed (pushed down) attempt to shift into Reverse gear. b. With the transmission in neutral, parking brake firmly set, start the engine and allow to idle. C. With the engine running, service brake fully applied, and the clutch pedal fully depressed (pushed down) attempt to shift into Reverse gear. 6. When attempting to engage Reverse gear, is the shift effort substantially higher (more difficult or unable to engage Reverse gear) when the engine is running, than when the engine is off? a. If YES »> then perform the Repair Procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Technical Service Bulletins > Customer Interest for Pressure Plate: > 06-001-07 > Feb > 07 > M/T - Difficult Gear Engagement > Page 9721 b. If NO »> then this Bulletin does not apply. Further diagnosis is required. PARTS REQUIRED: REPAIR PROCEDURE: NOTE:When the clutch pressure plate over-adjusts, the plate diaphragm fingers appear to be flat (collapsed) and marks on the clutch disc will be present due to contact with the collapsed plate diaphragm fingers. 1. Replace the dual mass flywheel, pressure plate, clutch disc, and plate attaching bolts. Refer to TechCONNECT for detailed service repair procedures. From TechCONNECT select: the "Service Info" tab and enter vehicle information (year, model, and engine). Select: 6 - Clutch > Flywheel and Disc - Clutch > Removal, Installation, and Adjustments. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Plate: > 06-001-07 > Feb > 07 > M/T - Difficult Gear Engagement Pressure Plate: All Technical Service Bulletins M/T - Difficult Gear Engagement NUMBER: 06-001-07 GROUP: Clutch DATE: February 03, 2007 SUBJECT: Clutch System May Over-Adjust Causing Difficulty Engaging Transmission Gear OVERVIEW: This bulletin involves replacement of the clutch system flywheel, pressure plate, and disc. MODELS: 2007 (DHID1IDC) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 5.9L or 6.7L Cummins turbo-diesel engine and the G56 manual transmission (sales code ETH, ETJ, and DEG respectively), and built on or before November 09, 2006 (MDH 1109XX). SYMPTOM/CONDITION: The customer may experience difficulty attempting to engage a manual transmission gear. This may be due to the self-adjusting mechanism in the clutch system. The self-adjusting clutch mechanism may over-adjust (forward adjust). This condition most often will occur within the first 1,000 miles of vehicle operation. DIAGNOSIS: 1. Inspect the clutch hydraulic system for leaks and or low fluid. 2. Is there a clutch system hydraulic leak and/or is the hydraulic fluid level low? a. If YES >> then repair the clutch hydraulic system. Proceed to the next step. b. If NO »> then proceed to the next step. 3. Evaluate the shift efforts of 1st gear when the engine is off and when the engine is running. a. With the engine off and the clutch pedal fully depressed (pushed down) attempt to shift into 1st gear. b. With the transmission in neutral, parking brake firmly set, start the engine and allow to idle. c. With the engine running, service brake fully applied, and the clutch pedal fully depressed (pushed down) attempt to shift into 1st gear. 4. When attempting to engage 1st gear, is the shift effort substantially higher (more difficult or unable to engage 1st gear) when the engine is running, than when the engine is off? a. If YES >> then perform the Repair Procedure b. If NO >> then proceed to the next step. 5. Evaluate the shift efforts of Reverse gear when the engine is off and when the engine is running. a. With the engine off and the clutch pedal fully depressed (pushed down) attempt to shift into Reverse gear. b. With the transmission in neutral, parking brake firmly set, start the engine and allow to idle. C. With the engine running, service brake fully applied, and the clutch pedal fully depressed (pushed down) attempt to shift into Reverse gear. 6. When attempting to engage Reverse gear, is the shift effort substantially higher (more difficult or unable to engage Reverse gear) when the engine is running, than when the engine is off? a. If YES »> then perform the Repair Procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Plate: > 06-001-07 > Feb > 07 > M/T - Difficult Gear Engagement > Page 9727 b. If NO »> then this Bulletin does not apply. Further diagnosis is required. PARTS REQUIRED: REPAIR PROCEDURE: NOTE:When the clutch pressure plate over-adjusts, the plate diaphragm fingers appear to be flat (collapsed) and marks on the clutch disc will be present due to contact with the collapsed plate diaphragm fingers. 1. Replace the dual mass flywheel, pressure plate, clutch disc, and plate attaching bolts. Refer to TechCONNECT for detailed service repair procedures. From TechCONNECT select: the "Service Info" tab and enter vehicle information (year, model, and engine). Select: 6 - Clutch > Flywheel and Disc - Clutch > Removal, Installation, and Adjustments. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Technical Service Bulletins > Page 9728 Pressure Plate: Specifications Pressure Plate Align and hold pressure plate in position and install bolts finger tight. Tighten bolts evenly and a few threads at a time in a diagonal pattern. CAUTION: Bolts must be tightened evenly and to specified torque to avoid warping pressure plate cover. Pressure Plate Bolts - V6 & V8 Tighten to ........................................................................................... ....................................................................................................... 50 Nm (37 ft.lbs.) Pressure Plate Bolts - Diesel Tighten to ...................................................................................................................... ............................................................................ 30 Nm (22 ft.lbs.) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Differential, CVT > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Differential, CVT > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 9735 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 9740 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal Actuator: Service and Repair Removal REMOVAL 1. Remove actuator wiring connector. 2. Remove actuator (1) bolts (2). 3. Remove actuator (1) from disconnect pocket (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal > Page 9747 Actuator: Service and Repair Installation INSTALLATION 1. Clean actuator (1) sealing surface and install new gasket (2) if necessary. 2. Align actuator shift fork (1) with disconnect collar (2) and install actuator on disconnect pocket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal > Page 9748 3. Install actuator (1) bolts (2) and tighten to 27 Nm (20 ft. lbs.). 4. Install disconnect actuator wiring connector. 5. Verify differential fluid level and add fluid if necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front Solenoid: Locations Module-Axle Disconnect-Front Component ID: 200 Component : MODULE-AXLE DISCONNECT-FRONT Connector: Name : MODULE-AXLE DISCONNECT-FRONT Color : DK. GRAY # of pins : 4 Qualifier : (LD 4WD) Pin Description Circuit 1 GROUND Z906 20BK 2 FRONT AXLE LOCK CONTROL G304 20VT/DB 3 FUSED B(+) A880 20DB/RD 4 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 35 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 9753 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 9754 Solenoid: Locations Solenoid-Locker-Front Component ID: 442 Component : SOLENOID-LOCKER-FRONT Connector: Name : SOLENOID-LOCKER-FRONT Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 FRONT LOCKER SOURCE T520 16YL/OR 2 LOCKER SENSOR SUPPLY T521 18YL/BK 3 FRONT LOCKER SENSOR SENSE T522 18YL/LB 4 FRONT LOCKER RETURN T524 16YL/LG Component Location - 36 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 9755 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 9756 Solenoid: Locations Solenoid-Locker-Rear Component ID: 443 Component : SOLENOID-LOCKER-REAR Connector: Name : SOLENOID-LOCKER-REAR Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 REAR LOCKER SOURCE T526 16YL/WT 2 LOCKER SENSOR SUPPLY T523 18YL/BK 3 REAR LOCKER SENSOR SENSE T527 18YL/TN 4 REAR LOCKER RETURN T528 16YL/GY Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 9757 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front Solenoid: Diagrams Module-Axle Disconnect-Front Component ID: 200 Component : MODULE-AXLE DISCONNECT-FRONT Connector: Name : MODULE-AXLE DISCONNECT-FRONT Color : DK. GRAY # of pins : 4 Qualifier : (LD 4WD) Pin Description Circuit 1 GROUND Z906 20BK 2 FRONT AXLE LOCK CONTROL G304 20VT/DB 3 FUSED B(+) A880 20DB/RD 4 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 35 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 9760 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 9761 Solenoid: Diagrams Solenoid-Locker-Front Component ID: 442 Component : SOLENOID-LOCKER-FRONT Connector: Name : SOLENOID-LOCKER-FRONT Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 FRONT LOCKER SOURCE T520 16YL/OR 2 LOCKER SENSOR SUPPLY T521 18YL/BK 3 FRONT LOCKER SENSOR SENSE T522 18YL/LB 4 FRONT LOCKER RETURN T524 16YL/LG Component Location - 36 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 9762 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 9763 Solenoid: Diagrams Solenoid-Locker-Rear Component ID: 443 Component : SOLENOID-LOCKER-REAR Connector: Name : SOLENOID-LOCKER-REAR Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 REAR LOCKER SOURCE T526 16YL/WT 2 LOCKER SENSOR SUPPLY T523 18YL/BK 3 REAR LOCKER SENSOR SENSE T527 18YL/TN 4 REAR LOCKER RETURN T528 16YL/GY Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 9764 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > Front Axle - C205FD Differential Cover: Service and Repair Front Axle - C205FD Removal REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Remove vent hose. 3. Remove differential cover (1) bolts (2). 4. Remove cover and drain lubricant. Installation INSTALLATION 1. Apply a 4 mm (0.15 in.) bead of Mopar(R) Silicone Rubber Sealant (1) or equivalent to the cover (2). CAUTION: If housing cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied. Failure to follow these instructions will result in a leak. 2. Install cover (2) and identification tag. Tighten cover bolts in a criss-cross pattern to 23 Nm (17 ft. lbs.). 3. Fill differential to specifications. 4. Install fill plug. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > Front Axle - C205FD > Page 9769 Differential Cover: Service and Repair Rear Axle - 9 1/4 Removal REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Remove drain plug. 3. Remove cover bolts. 4. Remove cover and drain lubricant. Installation INSTALLATION 1. Apply a 6.35mm (1/4 in.) bead of Mopar(R) Silicone Rubber Sealant (1) or equivalent to the cover (2). CAUTION: If housing cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied. Failure to follow these instructions will result in a leak. 2. Install cover and identification tag. Tighten cover bolts in a criss-cross pattern to 41 Nm (30 ft. lbs.). 3. Fill differential with lubricant to specifications. 4. Install fill plug. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Actuator, Differential Lock > Component Information > Service and Repair > Removal Actuator: Service and Repair Removal REMOVAL 1. Remove actuator wiring connector. 2. Remove actuator (1) bolts (2). 3. Remove actuator (1) from disconnect pocket (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Actuator, Differential Lock > Component Information > Service and Repair > Removal > Page 9775 Actuator: Service and Repair Installation INSTALLATION 1. Clean actuator (1) sealing surface and install new gasket (2) if necessary. 2. Align actuator shift fork (1) with disconnect collar (2) and install actuator on disconnect pocket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Actuator, Differential Lock > Component Information > Service and Repair > Removal > Page 9776 3. Install actuator (1) bolts (2) and tighten to 27 Nm (20 ft. lbs.). 4. Install disconnect actuator wiring connector. 5. Verify differential fluid level and add fluid if necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front Solenoid: Locations Module-Axle Disconnect-Front Component ID: 200 Component : MODULE-AXLE DISCONNECT-FRONT Connector: Name : MODULE-AXLE DISCONNECT-FRONT Color : DK. GRAY # of pins : 4 Qualifier : (LD 4WD) Pin Description Circuit 1 GROUND Z906 20BK 2 FRONT AXLE LOCK CONTROL G304 20VT/DB 3 FUSED B(+) A880 20DB/RD 4 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 35 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 9781 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 9782 Solenoid: Locations Solenoid-Locker-Front Component ID: 442 Component : SOLENOID-LOCKER-FRONT Connector: Name : SOLENOID-LOCKER-FRONT Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 FRONT LOCKER SOURCE T520 16YL/OR 2 LOCKER SENSOR SUPPLY T521 18YL/BK 3 FRONT LOCKER SENSOR SENSE T522 18YL/LB 4 FRONT LOCKER RETURN T524 16YL/LG Component Location - 36 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 9783 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 9784 Solenoid: Locations Solenoid-Locker-Rear Component ID: 443 Component : SOLENOID-LOCKER-REAR Connector: Name : SOLENOID-LOCKER-REAR Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 REAR LOCKER SOURCE T526 16YL/WT 2 LOCKER SENSOR SUPPLY T523 18YL/BK 3 REAR LOCKER SENSOR SENSE T527 18YL/TN 4 REAR LOCKER RETURN T528 16YL/GY Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 9785 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front Solenoid: Diagrams Module-Axle Disconnect-Front Component ID: 200 Component : MODULE-AXLE DISCONNECT-FRONT Connector: Name : MODULE-AXLE DISCONNECT-FRONT Color : DK. GRAY # of pins : 4 Qualifier : (LD 4WD) Pin Description Circuit 1 GROUND Z906 20BK 2 FRONT AXLE LOCK CONTROL G304 20VT/DB 3 FUSED B(+) A880 20DB/RD 4 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 35 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 9788 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 9789 Solenoid: Diagrams Solenoid-Locker-Front Component ID: 442 Component : SOLENOID-LOCKER-FRONT Connector: Name : SOLENOID-LOCKER-FRONT Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 FRONT LOCKER SOURCE T520 16YL/OR 2 LOCKER SENSOR SUPPLY T521 18YL/BK 3 FRONT LOCKER SENSOR SENSE T522 18YL/LB 4 FRONT LOCKER RETURN T524 16YL/LG Component Location - 36 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 9790 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 9791 Solenoid: Diagrams Solenoid-Locker-Rear Component ID: 443 Component : SOLENOID-LOCKER-REAR Connector: Name : SOLENOID-LOCKER-REAR Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 REAR LOCKER SOURCE T526 16YL/WT 2 LOCKER SENSOR SUPPLY T523 18YL/BK 3 REAR LOCKER SENSOR SENSE T527 18YL/TN 4 REAR LOCKER RETURN T528 16YL/GY Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 9792 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Differential: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 9797 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 9798 Fluid - Differential: Technical Service Bulletins Differential - Fluid Level Inspection Procedure NUMBER: 03-003-06 GROUP: Axle DATE: October 20, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 03-001-04 REV. A, DATED MAY 11, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS. SUBJECT: Axle Fluid Level MODELS: 2004 (AN) Dakota **2004 - 2007** (DR/DH/D1/DC) Ram Truck **2004 - 2007** (HB/HG) Durango / Aspen **2005 - 2007** (ND) Dakota DISCUSSION: The axle fill holes on some Dodge Truck vehicle axles may be located considerably higher than the actual fluid level. Filling the axle until the fluid comes out of the fill hole will over fill the axle, which may cause fluid foaming. When checking fluid level or filling a rear axle with fluid, you must measure the distance from the bottom of the fill hole to the top of the actual fluid level. This can easily be accomplished using a pipe cleaner or piece of wire. Make a 90 degree bend in the wire 2 inches from the end. The wire can then be inserted into the axle fill hole to use as a dipstick. Measure the distance from the bend to the oil level. The fluid levels for the axles are shown in the table below. CORRECT FLUID LEVELS FOR DURANGO / ASPEN: NOTE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 9799 The Trac-Lok feature is not available on Durango rear axles. Traction control is provided electronically through the ABS system. Trac-Lok additives or friction modifiers are not required. CORRECT FLUID LEVELS FOR RAM TRUCK 1500: CORRECT FLUID LEVELS FOR RAM TRUCK 2500 -3500: CORRECT FLUID LEVELS FOR DAKOTA: NOTE: The Trac-Lok feature is available on Dakota rear axles. Trac-Lok additives are required on axles equipped with Trac Lok. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications FRONT AXLE CAPACITY ± .03 L (1 oz.) C205FD ............................................................................................................................................... ............................................................. 1.6 L (56 oz.) 9 1/4 AA ........................................................... ................................................................................................................................................ 2.5 L (74 oz.) 9 1/4 AA EL ............................................................................................................................ ......................................................................... 2.0 L (68 oz.) REAR AXLE CAPACITY ± .03 L (1 oz.) 9 1/4 ..................................................................................................................................................... .......................................................... * 2.1 L (72 oz.) 10 1/2 AA ......................................................... ................................................................................................................................................ 2.5 L (85 oz.) 10 1/2 AA EL .......................................................................................................................... ......................................................................... 2.5 L (85 oz.) 11 1/2 AA open .................................... .......................................................................................................................................................... 4.2 L (142 oz.) 11 1/2 AA Trac-Rite ..................................................................................................... .................................................................................. 4.0 L (135 oz.) *With Trac-Lok add 118 ml (4 oz.) of Limited Slip Additive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 9802 Fluid - Differential: Fluid Type Specifications NOTE: DaimlerChrysler recommends using Mopar lubricants or lubricants of equal quality. FRONT AXLE LUBRICANT C205FD ............................................................................................................................................... ................. Mopar Synthetic Gear Lubricant 75W-90 9 1/4 AA ........................................................... .................................................................................................... Mopar Synthetic Gear Lubricant 75W-90 9 1/4 AA EL ......................................................................................................................................................... Mopar Synthetic Gear Lubricant 75W-90 REAR AXLE LUBRICANT 9 1/4 ..................................................................................................................................................... ............... Mopar Synthetic Gear Lubricant 75W-140 10 1/2 AA ............................................................................................................................................................. Mopar Synthetic Gear Lubricant 75W-90 10 1/2 AA EL ...................................................................................................................................................... Mopar Synthetic Gear Lubricant 75W-90 11 1/2 AA ............................................................................................................................................................ Mopar Synthetic Gear Lubricant 75W-90 NOTE: Trac-Lok differentials require Limited Slip Additive in the lubricant. Trac-Rite/Trac-Rite EL differentials DO NOT require Limited Slip Additive. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal Differential Output Shaft Bearing: Service and Repair Removal REMOVAL 1. Remove half shaft from disconnect side of the axle. 2. Remove disconnect actuator wiring connector. 3. Remove disconnect actuator (1) bolts (2) and remove actuator from disconnect pocket. 4. Remove O-ring (1) and snap ring (2) from output shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal > Page 9808 5. Remove disconnect seal (1) bolts (2). 6. Remove output shaft (1) and disconnect seal (2) with Remover 8420A (3) and Slide Hammer C-3752. 7. Slide disconnect collar (1) from intermediate shaft (2) and remove through disconnect pocket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal > Page 9809 8. Remove differential cover. 9. Drive intermediate shaft (1) out of side gear with a hammer and brass punch (2). 10. Remove intermediate shaft (1) from disconnect pocket (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal > Page 9810 11. Install Puller 9766 (1) in intermediate shaft bearing (2) then tighten nut (3) to expand tool in bearing. 12. Tighten puller (1) nut (2) to remove intermediate shaft bearing from disconnect pocket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal > Page 9811 Differential Output Shaft Bearing: Service and Repair Installation INSTALLATION 1. Install intermediate shaft bearing (1) with Installer 9767 (2) and Handle C-4171. CAUTION: Bearing must be installed with lettering facing outwards. Failure to follow these instructions will damage the bearing. 2. Install new intermediate shaft snap ring. 3. Install intermediate shaft (1) through disconnect pocket (2) and verify intermediate shaft snap ring is seated in side gear. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal > Page 9812 4. Install disconnect collar (1) through disconnect pocket onto intermediate shaft (2). 5. Position disconnect collar (1) on intermediate shaft (2) in 2WD position. 6. Verify output shaft bearing cup (1) is seated in disconnect pocket (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal > Page 9813 7. Install output shaft (1) in disconnect pocket (2). 8. Install disconnect seal (1) on output shaft (2). 9. Align disconnect seal (1) with bolt holes in disconnect pocket with Pins MD998412 (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal > Page 9814 10. Install disconnect seal (1) in disconnect pocket with Installer 6761 (2) and a hammer. 11. Install disconnect seal (1) bolts (2) and tighten to 28 Nm (21 ft. lbs.). 12. Install output shaft O-ring (1) and snap ring (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal > Page 9815 13. Clean actuator (1) sealing surface and install new gasket (2) if necessary. 14. Align actuator shift fork (1) with disconnect collar (2) and install actuator on disconnect pocket. 15. Install disconnect actuator (1) bolts (2) and tighten to 27 Nm (20 ft. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal > Page 9816 16. Install disconnect actuator wiring connector. 17. Install differential cover and fill differential to specification. 18. Install half shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD Seals and Gaskets: Service and Repair Front Axle - C205FD Removal REMOVAL 1. Remove half shaft from disconnect side of the axle. 2. Remove O-ring (1) and snap ring (2) from the output shaft. 3. Remove disconnect seal (1) bolts (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 9821 4. Remove output shaft and disconnect seal (1) with Remover 8420A (2) and Slide Hammer C-3752. Installation INSTALLATION 1. Verify output shaft bearing cup (1) is seated in disconnect pocket (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 9822 2. Install output shaft (1) in disconnect pocket (2). 3. Install disconnect seal (1) on output shaft (2). 4. Align disconnect seal (1) with bolt holes in disconnect pocket with Pins MD998412 (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 9823 5. Install disconnect seal (1) in disconnect pocket with Installer 6761(2) and a hammer. 6. Install disconnect seal (1) bolts (2) and tighten to 28 Nm (21 ft. lbs.). 7. Install output shaft O-ring (1) and snap ring (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 9824 8. Install half shaft. 9. Verify differential fluid level and add fluid if necessary. Removal REMOVAL 1. Remove half shaft from vehicle. 2. Clean axle seal area. 3. Remove O-ring (1) and snap ring (2) from axle shaft (3). 4. Remove axle with Remove 8420A (2,3,4) and Slide Hammer C-3752. 5. Remove axle shaft seal with a seal puller. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 9825 1. Wipe axle shaft tube bore clean. 2. Install new axle shaft seal with Installer 8694 (1). 3. Install axle shaft with new snap ring and verify axle shaft snap ring is seated in side gear. 4. Install O-ring (1) and snap ring (2) on axle shaft (3). 5. Install half shaft. 6. Verify differential fluid level and add fluid if necessary. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 9826 1. With axle in 2WD remove front propeller shaft and left half shaft. 2. Rotate pinion gear three or four times and verify pinion rotates smoothly. 3. Record pinion torque to rotate with an inch pound torque wrench (2), for installation reference. 4. Position Holder 6719 against the companion flange (1) and install a four bolts and washers into the threaded holes and tighten the bolts. 5. Remove pinion nut. 6. Mark a line across the pinion shaft and flange for installation reference. 7. Remove companion flange with (1) Remover C-452 (2). 8. Remove pinion seal with a seal puller. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 9827 1. Apply a light coating of gear lubricant on the lip of pinion seal. 2. Install seal with Installer 8695 (2) and Handle C-4171 (1). 3. Install flange on the pinion shaft with the reference marks aligned. 4. Install companion flange onto the pinion with Installer C-3718 and Holder 6719A. 5. Position holder (2) against the companion flange and install four bolts and washers into the threaded holes. Tighten the bolt and washer so that the holder is held to the flange. 6. Install a new pinion nut onto the pinion shaft and tighten the pinion nut until there is zero bearing end-play CAUTION: Do not exceed 271 Nm (200 ft. lbs.) the minimum tightening torque when installing the companion flange at this point. Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. Failure to follow these instruction will damage the axle. 7. Measure pinion Torque To Rotate with an inch pound torque wrench (2). Pinion Torque To Rotate should be equal to recorded reading plus an additional 0.56 Nm (5 in. lbs.). 8. If rotating torque is low, tighten the pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion Torque To Rotate is achieved. CAUTION: If maximum tightening torque 475 Nm (350 ft. lbs.) is reached prior to reaching the required rotating torque, the collapsible spacer may have been damaged. Failure to follow these instruction will damage the axle. 9. Install propeller shaft and half shafts. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 9828 Seals and Gaskets: Service and Repair Front Axle - 9 1/4 AA Removal REMOVAL 1. Remove hub bearings and axle shafts. 2. Remove differential from differential housing (2). 3. Remove differential bearing adjusters (1). 4. Remove axle seals (2) located behind adjusters with Receiver 8498 and Extractor 6310. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 9829 5. Install Receiver 8498 (1) into the adjuster bore. 6. Install Extractor Rod 6310 with Extractor Foot 6310-9 (2) through the receiver and axle seal. 7. Install Extractor Plate 6310-2 and Nut 6310-7 (2) on the extractor rod (1). 8. Tighten nut (2) on extractor rod (1) to pull seal into the receiver. Installation INSTALLATION 1. Install axle seal on Installer Cups 8885-2 (1) (3) and position cups with seals into the housing. NOTE: Seals are installed with the axle guide facing outward. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 9830 2. Install Turnbuckle 8885-1(2) into installer cups and expand the turnbuckle until the seals bottom out in the housing. 3. Install adjuster (1) into the differential housing (2). 4. Install differential in housing. 5. Install axle shaft and hub bearings. Removal REMOVAL 1. Mark propeller shaft and pinion flange (1) for installation reference. 2. Remove propeller shaft. 3. Remove hub bearings and axle shafts. 4. Rotate pinion gear three or four times. 5. Record pinion torque to rotate (1) with an inch pound torque wrench (2) for installation reference. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 9831 6. Hold pinion flange (1) with Flange Wrench 8979 (2) and remove pinion flange nut and washer. 7. Mark a line across the pinion shaft and flange for installation reference. 8. Remove pinion flange (1) with Pinion Flange Puller 8992 (2). 9. Remove pinion seal with a seal puller. Installation INSTALLATION 1. Install new pinion seal with Installer 8882 (2) and Handle C-4171 (1). 2. Apply a light coat of teflon thread sealant, to pinion flange splines. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 9832 3. Install flange on the pinion shaft with the reference marks aligned. 4. Lightly tap pinion flange onto the pinion, until a few threads are showing. 5. Install flange washer and new pinion nut. 6. Hold flange (1) with Flange Wrench 8979 (2) and tighten pinion nut until pinion end play is taken up. 7. Rotate pinion flange (1) several times to seat bearings. 8. Measure pinion torque to rotate (1) with an inch pound torque wrench (2). Pinion torque to rotate should be equal to recorded reading plus an additional 0.40-0.57 Nm (3-5 in. lbs.). 9. If torque to rotating is low, tighten the pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion torque to rotate is achieved. 10. Rotate pinion several times then verify pinion torque to rotate again. 11. Install axle shafts and hub bearings. 12. Install propeller shaft with reference marks aligned. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 9833 Seals and Gaskets: Service and Repair Rear Axle - 9 1/4 Removal REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal (1) from the axle tube with a seal puller. Installation INSTALLATION 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. 2. Coat the lip of the new seal with axle lubricant and install a seal with Installer C-4076-B and Handle C-4735. NOTE: When tool contacts the axle tube, the seal is installed to the correct depth. 3. Install the axle shaft (1). 4. Install differential cover and fill with gear lubricant to the bottom of the fill plug hole. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 9834 1. Mark universal joint, companion flange and pinion shaft for installation reference. 2. Remove propeller shaft from the companion flange. 3. Remove the brake rotors to prevent any drag. 4. Rotate companion flange three or four times. 5. Record pinion torque to rotating (1) with an inch pound torque wrench (2). 6. Install two bolts into the companion flange threaded holes, 180° apart. Position Holder 6719A against the companion flange and install and tighten two bolts and washers into the remaining holes. 7. Hold the companion flange with Holder 6719A and remove pinion nut and washer. 8. Mark a line across the pinion shaft and flange for installation reference. 9. Remove companion flange with Puller C-452 (2). 10. Remove pinion seal with seal puller or slide-hammer mounted screw. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 9835 1. Apply a light coating of gear lubricant on the lip of pinion seal. 2. Install new pinion seal (3) with Handle C-4735 and Installer C-4076-B (1). 3. Install flange on the pinion shaft with the reference marks aligned. 4. Install two bolts into the threaded holes in the companion flange, 180° apart. 5. Position Holder 6719A (2) against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so holder is held to the flange. 6. Install companion flange on pinion shaft with Installer C-3718 and Holder 6719A. 7. Install pinion washer and a new pinion nut. The convex side of the washer must face outward. 8. Hold companion flange with Holder 6719A (2) and tighten pinion nut with a torque wrench (3) to 285 Nm (210 ft. lbs.). NOTE: Do not exceed the minimum torque 285 Nm (210 ft. lbs.) when installing the pinion nut at this point. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 9836 9. Rotate pinion several times to ensure pinion bearings are seated. 10. Measure pinion torque to rotate (1) with an inch pound torque wrench (2). Pinion torque to rotate should be equal to recorded reading plus an additional 0.56 Nm (5 in. lbs.). If pinion torque to rotate is low, tighten pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion torque to rotating is achieved. CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque. If pinion torque to rotating is exceeded, a new collapsible spacer must be installed. Failure to follow these instructions will result in damage to the axle. 11. Install propeller shaft. 12. Install rear brake rotors components. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 9837 Seals and Gaskets: Service and Repair Rear Axle - 10 1/2 AA Removal REMOVAL 1. Remove axle shafts. 2. Mark propeller shaft and pinion flange for installation reference and remove shaft. 3. Rotate pinion gear three or four times. 4. Record pinion torque to rotate (1) with an inch pound torque wrench (2). 5. Hold pinion flange (1) with Wrench 8979 (2) and remove pinion flange nut and washer. 6. Mark a line across the pinion shaft and flange for installation reference. 7. Remove pinion flange (1) with Puller 8992 (2). 8. Remove pinion shaft seal with a pry tool or slide hammer mounted screw. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 9838 Installation INSTALLATION 1. Install new pinion seal with Installer 8896 (2) and Handle C-4171 (1). 2. Apply a light coat of teflon sealant to the pinion flange splines. 3. Install flange on the pinion shaft with the reference marks aligned. 4. Lightly tap the pinion flange onto the pinion until a few threads are showing. 5. Install flange washer and new pinion nut. 6. Hold flange (2) with Flange Wrench 8979 (1) and tighten pinion nut until pinion end play is taken up. 7. Rotate pinion several times to seat bearings. 8. Measure pinion torque to rotate (1) with an inch pound torque wrench (2). Pinion torque to rotate should be equal to recorded reading plus an additional 0.40-0.57 Nm (3-5 in. lbs.). 9. If torque to rotating is low, tighten the pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion torque to rotate is achieved. 10. Rotate pinion several times then verify pinion torque to rotate again. 11. Install axle shafts. 12. Install propeller shaft with reference marks aligned. 13. Check and fill differential if necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 9839 Seals and Gaskets: Service and Repair Rear Axle - 11 1/2 AA Removal REMOVAL 1. Remove axle shafts. 2. Mark the propeller shaft and pinion flange for installation reference. 3. Remove propeller shaft. 4. Rotate pinion gear (1) three or four times. 5. Measure and record the amount of torque necessary to rotate the pinion gear with an inch pound torque wrench (2). 6. Hold pinion flange (1) with Flange Wrench 8979 (2) and remove pinion flange nut. 7. Remove pinion flange (1) with Pinion Flange Puller 8992 (2). 8. Remove pinion shaft seal with a seal puller or slide hammer mounted screw. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 9840 Installation INSTALLATION 1. Install new pinion seal with Handle C-4171 (1) and Installer 8896 (2). 2. Apply a light coat of teflon sealant to the pinion flange splines. 3. Lightly tap the pinion flange onto the pinion until a few threads are showing. 4. Install flange washer and new pinion nut. 5. Hold pinion flange (2) with Flange Wrench 8979 (1) and tighten pinion nut until pinion end play is taken up. 6. Rotate pinion several times to seat bearings. 7. Measure pinion (1) Torque To Rotate with an inch pound torque wrench (2) and compare it to recorded measurement. Tighten pinion nut in small increments, until pinion Torque To Rotate is 0.40-0.57 Nm (3-5 in. lbs.) greater than recorded measurement. 8. Rotate pinion several times then verify pinion Torque To Rotate again. 9. Install axle shafts. 10. Install propeller shaft with reference marks aligned. 11. Check differential fluid level. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD Axle Bearing: Service and Repair Front Axle - C205FD Removal REMOVAL 1. Remove half shaft from vehicle. 2. Clean axle seal area. 3. Remove O-ring (1) and snap ring (2) from axle shaft (3). 4. Remove axle with Remove 8420A (2) (3) Collar 8420-3 (4) and Slide Hammer C-3752. 5. Remove axle shaft seal with a seal puller. 6. Install axle shaft bearing Remover C-4660-A (3) in the bearing (1). Then tighten the nut (2) to spread remover in the bearing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 9846 7. Install bearing remove cup (1) bearing (2) and nut (3). Tighten nut (3) to draw the bearing out. Installation INSTALLATION 1. Wipe axle shaft bearing bore clean. 2. Install axle shaft bearing with Installer 5063 (1) and Handle C-4171 (2). CAUTION: Bearing must be installer with lettering facing outwards. Failure to follow these instructions will damage the bearing. 3. Install a new axle shaft seal with Installer 8694 (1). 4. Lubricate seal lip with gear lubricant. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 9847 5. Install axle shaft with new snap ring and verify axle shaft snap ring is seated in side gear. 6. Install axle shaft (3) O-ring (1) and snap ring (2). 7. Install half shaft. 8. Verify differential fluid level and add fluid if necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 9848 Axle Bearing: Service and Repair Rear Axle - 9 1/4 Removal REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal from axle tube with a small pry bar. NOTE: The seal and bearing can be removed at the same time with the bearing removal tool. 3. Remove axle shaft bearing with Bearing Remover 6310 (2) (3) (4) (5) and Foot 6310-9 (7). Installation INSTALLATION 1. Wipe axle tube bore clean and remove any old sealer or burrs from the tube. 2. Install axle shaft bearing with Installer C-4198 and Handle C-4171. Drive bearing in until tool contacts the axle tube. NOTE: Bearing is installed with the bearing part number against the installer. 3. Coat lip of the new axle seal with axle lubricant and install with Installer C-4076-B and Handle C-4735. 4. Install the axle shaft (1). 5. Install differential cover and fill with gear lubricant to the bottom of the fill plug hole. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 9849 Axle Bearing: Service and Repair Rear Axle - 10 1/2 AA Removal REMOVAL 1. Remove axle shaft flange bolts and remove axle shaft. 2. Remove retainer ring (1) from axle shaft tube. 3. Remove hub bearing nut (1) locking key (2) from axle tube (3). 4. Remove hub bearing nut with Socket 8954. 5. Remove hub and bearings from the axle. 6. Pry out hub bearing seal from the back of the hub. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 9850 NOTE: The inner part of the seal (3) may stay on the axle tube (2). This part must also be removed with pry bar (1). 7. Remove rear bearing. 8. Remove hub bearing cups with a hammer and drift. Installation INSTALLATION 1. Install outer hub bearing cup with Installer 8961 and Handle C-4171. 2. Install inner hub bearing cup with Installer 8962 and Handle C-4171. 3. Pack bearings with the appropriate grease. 4. Install rear bearing and install new grease seal with Installer 8963 and Handle C-4171. 5. Slide hub on the axle tube and install front bearing into the hub. 6. Install hub bearing nut with Socket 8954 (1) and torque wrench (2) to 30 Nm (22 ft. lbs.) while rotating the hub. 7. Back off nut about 30° and align next hub nut key slot with axle tube key slot and install locking key. End play should be 0.025-0.25 mm (0.001-0.010 in.). 8. Install retainer ring (1) with ring end in the key slot (2). 9. Install new axle shaft gasket and install axle shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 9851 Axle Bearing: Service and Repair Rear Axle - 11 1/2 AA Removal REMOVAL 1. Remove axle shaft flange bolts and remove shaft. 2. Remove retainer ring (1) from the axle shaft tube. 3. Remove hub bearing nut (1) locking key (2) form axle tube (3). 4. Remove hub bearing nut with Socket 8954. 5. Remove hub and bearings from the axle. 6. Pry out hub bearing seal from the back of the hub. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 9852 NOTE: The inner part of the seal (3) may stay on the axle tube (2). This part must also be removed with a pry bar (1). 7. Remove rear bearing. 8. Remove hub bearing cups with a hammer and drift. Installation INSTALLATION 1. Install outer hub bearing cup with Installer 8961 and Handle C-4171. 2. Install inner hub bearing cup with Installer 8153 and Handle C-4171. 3. Pack bearings with the appropriate wheel bearing grease. 4. Install rear bearing and install new grease seal with Installer 8963 and Handle C-4171. 5. Slide hub on the axle tube and install front bearing into the hub. 6. Install hub bearing nut with Socket 8954 (1) and tighten with torque wrench (2) to 30 Nm (22 ft. lbs.) while rotating the hub. 7. Back off nut about 30° and align next hub nut key slot with axle tube key slot and install locking key. NOTE: End play should be 0.025-0.25 mm (0.01-0.001 in.) 8. Install retainer ring (1) with ring end in the key slot (2). 9. Install new axle shaft gasket and install the axle shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures Axle Shaft: Procedures Removal REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Position a lift under axle and secure axle to lift. 3. Remove all brake components. 4. Remove axle vent hose. 5. Mark propeller shaft and companion flange for installation alignment reference. 6. Remove propeller shaft. 7. Remove shock absorbers (3) from axle (2). 8. Remove U-bolts (5) from axle. 9. Remove axle from the vehicle. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9858 1. Raise axle with lift and align to the leaf spring centering bolts. 2. Install axle U-bolts (5) and tighten to 149 Nm (110 ft. lbs.). 3. Install shock absorbers to axle and tighten to specification. 4. Install all brake components. 5. Install axle vent hose. 6. Install propeller shaft with reference marks aligned and tighten to specification. 7. Fill differential to specifications. Removal REMOVAL 1. Remove axle shaft flange (1) bolts (2). 2. Slide axle shaft out of the axle tube. 3. Remove axle shaft gasket. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9859 NOTE: Axle flange bolts must be replaced or cleaned existing bolts apply Mopar(R) Lock N' Seal or Loctite(R) 242 on the threads. 1. Clean axle flange and hub. 2. Install new axle shaft gasket. 3. Slide axle shaft into the axle tube. 4. Install axle shaft flange (1) bolts (2) and tighten to 129 Nm (95 ft. lbs.). Removal REMOVAL 1. Remove axle shaft flange (1) bolts (2). 2. Slide axle shaft out of the axle tube. 3. Remove axle shaft gasket. Installation INSTALLATION NOTE: Axle flange bolts must be replaced or use Mopar(R) Lock N' Seal or Loctite(R) 242 on cleaned existing bolts. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9860 1. Clean axle flange and hub. 2. Install new axle shaft gasket. 3. Slide axle shaft into the axle tube. 4. Install axle shaft flange (1) bolts (2) and tighten to 129 Nm ( 95 ft. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9861 Axle Shaft: Removal and Replacement Removal REMOVAL 1. Remove half shaft from vehicle. 2. Clean axle seal area. 3. Remove O-ring (1) and snap ring (2) from axle shaft (3). 4. Remove axle with Remove 8420A (2,3,4) and Slide Hammer C-3752. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9862 1. Lubricate bearing bore and seal lip with gear lubricant. 2. Install axle shaft with new snap ring and verify axle shaft snap ring is seated in side gear. 3. Install O-ring (1) and snap ring (2) on axle shaft (3). 4. Install half shaft. 5. Verify differential fluid level and add fluid if necessary. Removal REMOVAL 1. With the vehicle in neutral, position vehicle on hoist. 2. Remove brake caliper, rotor and ABS wheel speed sensor if equipped. 3. Remove axle shaft (2) cotter pin (3), hub nut (1) and washer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9863 4. Remove four hub bearing bolts (2) from the back of the steering knuckle. 5. Remove hub bearing from the steering knuckle. 6. Remove axle shaft (2) from steering knuckle (1) and axle housing. Installation INSTALLATION 1. Clean axle shaft and apply a thin film of grease to the shaft splines and hub bore. 2. Install axle shaft (2) through the steering knuckle (3) and into the differential side gears. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9864 3. Install hub bearing in the knuckle. 4. Install hub bearing bolts (2) and tighten to 202 Nm (149 ft. lbs.). 5. Install ABS wheel speed sensor, brake rotor and caliper. 6. Install axle (2) washer and nut (1). Tighten axle nut to 179 Nm (132 ft. lbs.). 7. Rotate axle several 5 to 10 times to seat the wheel bearing. 8. Tighten axle nut (1) to final torque of 356 Nm (263 ft. lbs.). 9. Align nut to next cotter pin hole and install new cotter pin (3). Removal REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Position a lift under axle and secure lift to the axle. 3. Remove all brake components. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9865 4. Remove axle vent hose. 5. Mark propeller shaft and companion flange for installation alignment reference. 6. Remove propeller shaft. 7. Remove shock absorbers (3) from axle (2). 8. Remove U-bolts (5) from axle. 9. Remove axle from the vehicle. Installation INSTALLATION 1. Raise axle with lift and align to the leaf spring centering bolts. 2. Install axle U-bolts (5) and tighten to 149 Nm (110 ft. lbs.). 3. Install shock absorbers to axle and tighten to specification. 4. Install all brake components. 5. Install axle vent hose. 6. Install propeller shaft with reference marks aligned and tighten to specification. 7. Fill differential to specifications. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9866 1. Remove lubricant fill hole plug from the differential housing cover. 2. Remove differential housing cover and drain the lubricant from housing. 3. Remove axle shafts. 4. Remove adjuster lock bolts (1) and adjuster locks (2). 5. Mark bearing caps (4) left and right for installation reference. 6. Remove bearing cap bolts and remove bearing caps. 7. Loosen differential bearing (1, 3) adjusters (2, 4) with a hammer and punch. 8. Remove differential case from the housing. 9. Remove bearing cups (1, 3) and tag them left and right for installation reference. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9867 1. Clean housing (1) cavity with a flushing oil, light engine oil or lint free cloth. CAUTION: Do not use water, steam, kerosene or gasoline for cleaning. 2. Lubricate differential case bearing. 3. Install differential case with bearings cups into the housing. NOTE: A light coat of grease on the cups will hold them in place during installation. 4. Install bearing caps (2) and bolts. Tighten bearing cap bolts finger-tight. 5. Slide differential case (2) toward the pinion gear until the gears make contact/zero backlash. If zero backlash cannot be obtained, turn the pinion side adjuster until zero backlash is obtained. 6. Holding the differential case toward the pinion gear, turn bearing adjusters with Adjuster Wrench 8883A (1) until they make contact with the differential bearings/cups. 7. Back off the ring gear side adjuster 4 holes, to obtain initial ring gear backlash. 8. Install ring gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time. 9. Tighten pinion gear side adjuster firmly against the differential case bearing cup. 10. Rotate the pinion several times to seat the differential bearings. 11. Loosen pinion gear side adjuster until it is no longer in contact with the bearing cup. 12. Tighten pinion gear side adjuster until it just makes contact with the bearing cup. 13. Tighten pinion gear side adjuster an additional: - New Bearings 6 Adjuster Holes - Original Bearings 4 Adjuster Holes 14. Install pinion gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9868 15. Tighten bearing cap bolts to 165 Nm (122 ft. lbs.). 16. Tighten adjuster (2) lock bolts (3) to 25 Nm (18 ft. lbs.). 17. Measure ring gear backlash and check gear tooth contact pattern. Refer to Adjustments for procedure. 18. Install axle shafts. 19. Install differential housing gasket and cover. Tighten cover bolts to 40 Nm (30 ft. lbs.). 20. Fill differential with lubricant to specifications. 21. Install fill plug and tighten to 32 Nm (24 ft. lbs.). Removal REMOVAL 1. Remove differential case from the housing. 2. Install Plug 8888 (4) into the end of the case. 3. Remove differential case bearings (3) with Bearing Splitter 1130 (2) and Bridge 938 (1). Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9869 1. Install open and Trac-Rite differential case (2) bearings (3) with Installer 8956 (4) and Handle C-4171 (1). 2. Install differential case into housing. Removal REMOVAL 1. Remove the differential case from the housing. 2. Install Plug 8888 (1) into the end of the differential case on the coil side. 3. Install Puller 6444 (2) onto the end of the plug (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9870 4. Install puller Jaws 9915 (1) onto puller (2) and around the bearing. 5. Install puller collar (1) onto puller jaws (2). Tighten puller bolt and remove bearing. NOTE: Bearing on the other side of the case can be removed with Puller C-293-PA and Adapters 9614. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9871 1. Install differential bearings (1) with Handle C-4171 (2) and Installer 8956 (3). Removal REMOVAL NOTE: The ring and pinion gears are service in a matched set. Never replace the ring gear/pinion gear without replacing the other matching gear. 1. Mark pinion flange and propeller shaft for installation alignment. 2. Disconnect propeller shaft from pinion flange and remove propeller shaft. 3. Remove differential from axle housing. 4. Place differential on Plug 8888 and drive exciter ring (4) off the differential case (1) with a hammer and punch (3). NOTE: Do not remove the exciter ring if it is not being replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9872 5. Place differential case in a vise with soft metal jaw protectors. 6. Remove bolts holding ring gear to differential case. 7. Drive ring gear (2) from differential case (1) with a soft hammer (3). 8. Hold pinion flange (1) with Flange Wrench 8979 (2) and remove pinion flange nut and washer. 9. Remove pinion flange (1) from the pinion with Flange Puller 8992 (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9873 10. Remove pinion gear (1) from housing, with Pinion Driver 8977 (2) and a hammer. NOTE: Thread the driver on the pinion shaft till it bottoms out. 11. Remove pinion seal with a slide hammer or pry bar. 12. Remove and discard front pinion bearing. CAUTION: Do not reuse front pinion bearing/cup. 13. Remove collapsible spacer from the pinion shaft. 14. Remove rear pinion bearing with Puller C-293-PA (1) and Adapter Blocks 8879 (4). 15. Remove pinion depth shim from pinion gear shaft and record shim thickness. 16. Remove front pinion bearing cup from the housing with a punch and hammer and discard cup. CAUTION: Do not reuse front pinion bearing/cup. 17. Remove rear pinion bearing cup from the housing with a punch and hammer, if bearing is going to be replaced. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9874 1. Install new front pinion bearing cup with Installer 8960 (1) and Handle C-4171 (2). 2. Install new rear pinion bearing cup with Installer 8959 (1) and Handle C-4171 (2). 3. Install pinion depth shim (1) on the pinion gear shaft (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9875 4. Install rear pinion bearing (4) on pinion (3) with Installer MD-998805 (2) and a press (1). 5. Install new collapsible spacer (1) on pinion gear (2). 6. Lubricate pinion and bearings. 7. Install pinion into housing (2) and place front pinion bearing onto the pinion shaft. Draw pinion shaft into the front bearing with Installer 8981 (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9876 8. Install new pinion seal with Installer 8896 (2) and Handle C-4171 (1). 9. Apply a light coat of teflon sealant to the pinion flange splines. 10. Hold the pinion and lightly tap the pinion flange onto the pinion, until a few threads are showing. 11. Install pinion flange washer and new pinion nut. 12. Hold pinion flange (2) with Flange Wrench 8979 (1) and tighten pinion nut until pinion end play is taken up. 13. Rotate pinion several times to seat pinion bearings. 14. Measure Pinion Torque To Rotate (1) with an inch pound torque wrench (2). Tighten pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion torque to rotate is achieved. Pinion Torque To Rotate is: - New Pinion Bearings: 1.7 - 2.8 Nm (15 - 25 in. lbs.) - Original Pinion Bearings: 1.1 - 2.2 Nm (10 - 20 in. lbs.) 15. Rotate pinion several times then verify pinion torque to rotate again. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9877 16. Position ring gear (2) on differential case (4) and start two new ring gear bolts. 17. Install the rest of the new ring gear bolts and tighten them alternately to seat the ring gear. 18. Torque ring gear bolts to 237 Nm (175 ft. lbs.). 19. If exciter ring was removed, position differential assembly on differential Plug 8888 and place exciter ring on the differential case. 20. Install exciter ring (1) on the differential case evenly with a hammer and brass punch (2). Drive the ring down until it is seated against the ring gear (3). CAUTION: Do not damage exciter ring teeth during installation. 21. Install differential into the housing. 22. Verify ring gear backlash and gear contact pattern. 23. Measure Total Torque to Rotate (TTTR) with an inch pound torque wrench. Total Torque To Rotate is: - New Bearings: 3.4 - 5.6 Nm (30 - 50 in. lbs.) - Original Bearings: 2.8 - 5.1 Nm (25 - 45 in. lbs.) If TTTR is to high back off adjusters evenly on both sides slightly and check TTTR again. If TTTR is to low tighten adjusters evenly on both sides slightly and check TTTR again. 24. Install axle shafts. 25. Install the propeller shaft with the reference marks aligned. 26. Install differential cover with gasket and tighten bolts to 40 Nm (30 ft. lbs.). 27. Fill differential with fluid and tighten fill plug to 32 Nm (24 ft. lbs.). Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9878 1. Remove lubricant fill hole plug from the differential housing cover. 2. Remove differential housing cover and drain the lubricant from housing. 3. Remove axle shafts. 4. Cut sensor wire tie strap (4) from adjuster lock. 5. Remove sensor target magnet (1) from bearing cap. 6. Remove adjuster lock bolts (3) and adjuster locks (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9879 7. Remove electric locker connector (1) retainer (2) bolt from differential housing. 8. Remove connector (1) and retainer (2) from differential housing. 9. Remove retainer (1) from connector and remove O-ring (2) from connector. 10. Mark bearing caps (2) left and right for installation reference. 11. Remove bearing cap bolts and remove bearing caps (2). 12. Loosen differential bearing adjusters (3) with a hammer and punch. 13. Slid electric locker connector through differential housing. 14. Remove differential case with bearing cups from the housing. 15. Tag bearing cups left and right for installation reference. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9880 1. Clean the housing cavity with a flushing oil, light engine oil or lint free cloth. 2. Lubricate differential case bearing. 3. Install differential case with bearings cups into the housing. 4. Slide electric locker connector through differential housing. 5. Install O-ring (2) on electric locker connector. 6. Install electric locker connector retainer (1) and install connector with retainer in differential housing. 7. Install connector retainer bolt. 8. Install bearing caps (2) and tighten bearing cap bolts finger-tight. NOTE: Do not torque bearing cap and bolts at this time. 9. Slide differential case toward the pinion gear until the gears make contact/zero backlash. If zero backlash cannot be obtained, turn the pinion side adjuster until zero backlash is obtained. 10. Holding the differential case toward the pinion gear, turn bearing adjusters with Adjuster Wrench 8883A until they make contact with the differential bearings/cups. 11. Back off the ring gear side adjuster 4 holes, to obtain initial ring gear backlash. 12. Install ring gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time. 13. Tighten pinion gear side adjuster firmly against the differential case bearing cup. 14. Rotate the pinion several times to seat the differential bearings. 15. Loosen pinion gear side adjuster until it is no longer in contact with the bearing cup. 16. Tighten pinion gear side adjuster until it just makes contact with the bearing cup. 17. Tighten pinion gear side adjuster an additional: - New Bearings: 6 Adjuster Holes - Original Bearings: 4 Adjuster Holes 18. Install pinion gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9881 19. Tighten bearing cap bolts (4) to 165 Nm (122 ft. lbs.). 20. Tighten adjuster (2) lock bolts (3) to 25 Nm (18 ft. lbs.). 21. Measure ring gear backlash and check gear tooth contact pattern. Refer to Adjustments for procedure. 22. Install axle shafts. 23. Install sensor target magnet (1) on bearing cap. 24. Energize locker and rotate axle shaft. Verify dog clutch is engaged by rotating one axle while holding the other. If engaged axle will not rotate. 25. De-energize locker and rotate left axle 15 to 40 degrees so dog clutch gears will not engage. 26. Energize locker and set sensor air gap (2) to 5.5 mm ± 0.25 mm (0.21 in. ± 0.01 in.). NOTE: System will time out within 2 minutes, when the key is in the on position and the engine is not running. 27. Tighten sensor target magnet bolt (3) to 7 Nm (62 in. lbs.). 28. Hold right axle and rotate left axle until dog clutch engages with an audible click nose. NOTE: This will verify the sensor air gap was adjusted with the dog clutch gears ear to ear. 29. Install sensor wire tie strap (4) in the original location or at white dot on wiring harness to the top leg of adjuster lock and de-energize coil. 30. Install differential housing gasket and cover. Tighten cover bolts to 40 Nm (30 ft. lbs.). 31. Fill differential with lubricant to specifications. 32. Install fill plug and tighten to 32 Nm (24 ft. lbs.). Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9882 1. With vehicle in neutral, position vehicle on hoist. 2. Position a lift under axle and secure lift to the axle. 3. Remove all brake components. 4. Mark propeller shaft and companion flange for installation alignment reference. 5. Remove propeller shaft. 6. Remove axle vent hose. 7. Remove shock absorbers (3) from axle (2). 8. Remove U-bolts (4) from axle. 9. Remove axle from the vehicle. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9883 1. Raise axle with lift and align to the leaf spring (1) centering bolts. 2. Install axle U-bolts (5) and tighten to 149 Nm (110 ft. lbs.). 3. Install shock absorbers to axle and tighten to specification. 4. Install all brake components. 5. Install propeller shaft with reference marks aligned and tighten to specification. 6. Install axle vent hose. 7. Fill differential to specifications. 8. Remove lift from axle and lower the vehicle. Removal REMOVAL 1. Remove fill hole plug from the differential housing cover. 2. Remove differential housing cover and drain the lubricant. 3. Remove axle shafts. 4. Remove adjuster (3) lock bolts (1) and adjuster locks (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9884 5. Mark bearing caps left and right for installation reference. 6. Remove bearing cap bolts and remove bearing caps. 7. Loosen differential bearing (1, 3) adjusters (2, 4) with a hammer and punch. 8. Remove differential case from the housing. 9. Remove bearing cups (1, 3) and tag them left and right for installation reference. Installation INSTALLATION 1. Clean the housing cavity with a flushing oil, light engine oil or lint free cloth. NOTE: Do not use water, steam, kerosene or gasoline for cleaning. 2. Lubricate differential case bearing. 3. Install differential case with bearings cups into the housing. NOTE: A light coat of grease on the cups will hold them in place during installation. 4. Install bearing caps (2) and bolts. Tighten the bearing cap (2) bolts finger-tight. NOTE: Do not torque bearing cap and bolts at this time. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9885 5. Slide differential case toward the pinion gear until the gears make contact/zero backlash. If zero backlash cannot be obtained, turn the pinion side adjuster until zero backlash is obtained. 6. Holding the differential case (2) toward the pinion gear, turn bearing adjusters with Adjuster Wrench 8883A (1) until they make contact with the differential bearings/cups. 7. Back off the ring gear side adjuster 4 holes, to obtain initial ring gear backlash. 8. Install ring gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time. 9. Tighten pinion gear side adjuster firmly against the differential case bearing cup. 10. Rotate the pinion several times to seat the differential bearings. 11. Loosen pinion gear side adjuster until it is no longer in contact with the bearing cup. 12. Tighten pinion gear side adjuster until it just makes contact with the bearing cup. 13. Tighten pinion gear side adjuster an additional: - New Bearings 6 Adjuster Holes - Original Bearings 4 Adjuster Holes 14. Install pinion gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time. 15. Tighten bearing cap bolts (4) to 281 Nm (207 ft. lbs.). 16. Tighten adjuster lock bolts (3) to 25 Nm (18 ft. lbs.). 17. Measure ring gear backlash and check gear tooth contact pattern. Refer to Adjustments for procedure. 18. Install axle shaft gasket and install axle shafts. 19. Install differential housing gasket and cover. Tighten cover bolts to 40 Nm (30 ft. lbs.). 20. Fill differential with lubricant to specifications. 21. Install fill plug and tighten to 32 Nm (24 ft. lbs.). Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9886 1. Remove differential case from the housing. 2. Install Plug 8964 (4) into the end of the case. 3. Remove differential case bearings (3) with Bearing Splitter 1130 (2) and Bridge 938 (1). Installation INSTALLATION WARNING: Use welding gloves when handling heated components. Failure to follow these instructions will result in personal injury. CAUTION: A bearing heater (2) is used to install Trac-Rite differential case bearings (1). Use only a bearing heater/hot plate and follow manufacture's instructions. Heat components to 100 - 177 Celsius (212° - 350° Max Fahrenheit). Never use an open flame to heat components. Never leave components on heater for and extended amount of time. If component is discolored after heating the component has been overheated and must not be used. Failure to follow these instructions will result in component damage. 1. Heat Trac-Rite(R) differential case bearings (1) with bearing heater (2). 2. With welding gloves or tongs install bearings on differential case. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9887 3. Install open differential case (2) bearings (3) with Installer 8965 (4) and Handle C-4171 (1). 4. Install differential case into housing. Removal REMOVAL NOTE: The ring and pinion gears are service in a matched set. Never replace the ring gear/pinion gear without replacing the other matching gear. 1. Mark pinion flange and propeller shaft for installation alignment. 2. Remove propeller shaft. 3. Remove differential from the housing. 4. Place differential case (1) on Plug 8964. Drive exciter ring (4) off the differential case with a hammer and punch (3). NOTE: Do not remove the exciter ring if it is not being replaced. 5. Place differential case in a vise with soft metal jaw protectors. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9888 6. Remove bolts holding ring gear to differential case. 7. Drive ring gear (2) from differential case (1) with a soft hammer (3). 8. Hold pinion flange (1) with Flange Wrench 8979 (2) and remove pinion flange nut. 9. Remove pinion flange (1) from pinion with pinion Puller 8992 (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9889 10. Remove pinion gear (1) from housing with pinion Driver 8977 (2) and a hammer. NOTE: Thread the driver on the pinion shaft till it bottoms out. 11. Remove pinion seal with a slide hammer or pry bar. 12. Remove front pinion bearing and discard bearing. NOTE: Do not reuse front pinion bearing/cup. 13. Remove collapsible spacer from the pinion shaft. 14. Remove rear pinion bearing (1) with Bearing Splitter 1130 (2) and a press. 15. Remove pinion depth shim from the pinion gear shaft and record thickness of the shims. 16. Remove front pinion bearing cup from the housing with a punch and hammer, and discard cup. NOTE: Do not reuse front pinion bearing/cup. 17. Remove rear pinion bearing cup from the housing with a punch and hammer, if bearing is going to be replaced. Installation INSTALLATION 1. Install new front pinion bearing cup with Installer 8960 (1) and Handle C-4171 (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9890 2. Install new rear pinion bearing cup with Installer 8968 (1) and Handle C-4171 (2). 3. Install pinion depth shim (1) on the pinion gear shaft (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9891 4. Install rear pinion bearing (4) with Installer D-389 (1) and a press (1). 5. Install new collapsible spacer (1) on the pinion (2). 6. Lubricate pinion and bearings. 7. Install pinion into the housing (2) and place front pinion bearing onto the pinion shaft. Draw the pinion shaft into the front bearing with Installer 8981 (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9892 8. Install new pinion seal with Installer 8896 (2) and Handle C-4171 (1). 9. Apply a light coat of teflon sealant to the pinion flange splines. 10. Hold pinion and lightly tap the pinion flange (2) onto the pinion, until a few threads are showing. 11. Install pinion flange washer and new pinion nut. 12. Hold pinion flange (2) with Flange Wrench 8979 (1) and tighten pinion nut until pinion end play is eliminated. 13. Rotate pinion several times to seat pinion bearings. 14. Measure Pinion Torque To Rotate (1) with an inch pound torque wrench (2). Tighten pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion torque to rotate is achieved. Pinion Torque To Rotate is: - New Pinion Bearings: 1.7 - 2.8 Nm (15 - 25 in. lbs.) - Original Pinion Bearings: 1.1 - 2.2 Nm (10 - 20 in. lbs.) 15. Rotate pinion several times then verify pinion rotating torque again. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 9893 16. Position the ring gear (2) on differential case (4) and start two new ring gear bolts. 17. Install the rest of the new ring gear bolts and tighten them alternately to seat the ring gear. 18. Torque ring gear bolts to 237 Nm (175 ft. lbs.). 19. If exciter ring was removed, position differential assembly on differential Plug 8965 and place exciter ring (1) on the differential case. 20. Install the exciter ring on the differential case evenly with a hammer and brass punch (2). Drive the ring down until it is seated against the ring gear (2). 21. Install differential in housing and verify gear backlash and gear contact pattern. 22. Measure Total Torque To Rotate (TTTR) with an inch pound torque wrench. Total Torque To Rotate is: - New Bearings: 3.4 - 5.6 Nm (30 - 50 in. lbs.) - Original Bearings: 2.8 - 5.1 Nm (25 - 45 in. lbs.) If TTTR is to high, back off adjusters evenly on both sides slightly and check TTTR again. If TTTR is to low, tighten adjusters evenly on both sides slightly and check TTTR again. 23. Install axle shafts. 24. Install the propeller shaft with the reference marks aligned. 25. Install differential cover with gasket and tighten bolts to 40 Nm (30 ft. lbs.). 26. Fill differential with fluid and tighten fill plug to 32 Nm (24 ft. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint-Outer Constant Velocity Joint: Service and Repair CV Joint-Outer Removal REMOVAL 1. Clamp shaft in a vise (with soft jaws) and support C/V joint. CAUTION: Do not damage C/V housing or half shaft. 2. Remove clamps (2) (4) with a cut-off wheel or grinder. 3. Slide the boot down the shaft. 4. Remove lubricant to expose the C/V joint snap ring (1). 5. Spread snap ring (1) and slide the joint off the shaft. 6. Slide boot off the shaft and discard old boot. 7. Mark alignment marks (1) on the inner race/hub (2), bearing cage (3) and housing with dabs of paint. 8. Clamp C/V joint in a vertical position in a soft jawed vise. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint-Outer > Page 9898 9. Press down one side of the bearing cage (3) to gain access to the ball at the opposite side. NOTE: If joint is tight, use a hammer and brass drift to loosen the bearing hub. Do not contact the bearing cage with the drift. 10. Remove ball (4) from the bearing cage (3). 11. Repeat step above until all six balls are removed from the bearing cage. 12. Lift cage and inner race (2) upward and out from the housing (1). 13. Turn inner race 90° in the cage and rotate the inner race/hub out of the cage. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint-Outer > Page 9899 NOTE: If C/V joint is worn, replace entire C/V joint and boot. 1. Clean all C/V joint components and shaft. 2. Apply a light coat of grease supplied with the joint/boot to the C/V joint components before assembling them. 3. Align the inner race (1) cage (2) and housing according to the alignment reference marks. 4. Insert the inner race (1) into the cage (2) and rotate race into the cage. 5. Rotate the inner race/hub (2) in the cage. 6. Insert cage (2) into the housing. Rotate the cage 90° into the housing (3) so the large bearing hub counterbore is facing outwards. 7. Apply the grease supplied with the joint/boot to the ball races. Spread the grease equally between all the races. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint-Outer > Page 9900 8. Tilt inner race/hub (1) and cage (3) and install the balls(4). 9. Place new clamps onto new boot and slide boot onto the shaft to it's original position. 10. Apply the rest of grease to the C/V joint and boot. 11. Install the joint onto the shaft (2). Push the joint onto the shaft until the snap ring (1) seats in the groove (3). NOTE: Pull on the joint to verify the span ring has engaged. 12. Position the boot on the joint in it's original position. NOTE: Verify boot is not twisted and remove any excess air. 13. Secure both boot (5) clamps (2) (4) with Clamp Installer C-4975A. Place tool on clamp bridge and tighten tool until jaws of the tool are closed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint-Outer > Page 9901 Constant Velocity Joint: Service and Repair CV Joint-Inner Removal REMOVAL 1. Clamp shaft in vise (with soft jaws) and support C/V joint. 2. Remove clamps (2) (4) with a cut-off wheel or grinder. CAUTION: Do not damage C/V housing or half shaft with cut-off wheel or grinder. 3. Remove housing (2) from the half shaft and slide boot (1) down shaft. 4. Remove housing bushing from the housing. 5. Remove tripod (2) snap ring (1). 6. Remove tripod (2) and boot from the half shaft. 7. Clean and inspect C/V components for excessive wear and damage. Replace the tripod as a unit only if necessary. Installation Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint-Outer > Page 9902 INSTALLATION 1. Clean all C/V joint components and shaft. 2. Slide new boot (1) down the half shaft. 3. Install tripod (2) and tripod snap ring on the half shaft. 4. Pack grease supplied with the joint/boot into the housing and boot. 5. Coat tripod with supplied grease. 6. Install new bushing (1) onto the housing (2). 7. Insert the tripod and shaft in the housing. 8. Position the boot (2) on the housing (5) and shaft (4) in it's original position. NOTE: Verify boot is not twisted and remove any excess air. 9. Measure the distance from the end of the housing to the end of the boot on the shaft. This measurement should be 260 mm (10.25 in.). NOTE: If measurement is not correct, allow more or less air into the boot. 10. Secure both boot clamps (1) (3) with Clamp Installer C-4975A. Place tool on clamp bridge and tighten tool until the jaws of the tool are closed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Removal Universal Joint: Service and Repair Removal REMOVAL NOTE: Saturate bearing caps with penetrating oil prior to removal. 1. Remove axle shaft. 2. Remove bearing cap snap rings (1) from stub shaft yoke (2) bearing caps. 3. Position receiver/socket (2) and driver/socket (1) on stub shaft yoke (3) in press. Press bearing cup into receiver/socket (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Removal > Page 9907 4. Remove bearing cap (1) from stub shaft yoke (2). 5. Position receiver/socket (2) under stub shaft yoke (3) remaining bearing cup and driver/socket (1) on U-joint cross in press. Press bearing cup into receiver/socket (2) 6. Remove bearing cap (1) from stub shaft yoke (2). Then remove stub shaft from U-joint cross. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Removal > Page 9908 7. Remove snap rings (1) from shaft yoke (2) bearing caps. 8. Position receiver/socket (2) and driver/socket (1) on shaft yoke (3) in press. Press bearing cup into receiver/socket (2). 9. Remove bearing cap (1) from shaft yoke (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Removal > Page 9909 10. Position receiver/socket (2) under shaft yoke (3) remaining bearing cup and driver/socket (1) on U-joint cross in press. Press bearing cup into receiver/socket (2) 11. Remove bearing cap (1) from shaft yoke (2). Then remove U-joint cross from shaft yoke. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Removal > Page 9910 Universal Joint: Service and Repair Installation INSTALLATION CAUTION: Keep cross and bearing cap straight during installation. Failure to follow these instruction will result in damage. 1. Pack bearing caps 1/3 full of wheel bearing lubricant. Apply extreme pressure (EP), lithium-base lubricant to aid in installation. 2. Position cross (1) in the shaft yoke (2). 3. Tap bearing cap into the yoke bores far enough to position cross. 4. Position receiver/socket (1) on shaft yoke and driver/socket (2) on bearing cap in press. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Removal > Page 9911 5. Press bearing cap into shaft yoke (1) until bearing cap snap ring groove is visible and install snap ring (2). 6. Position receiver/socket (1) on shaft yoke and driver/socket (2) on bearing cap in press. 7. Press bearing cap into shaft yoke (1) until bearing cap snap ring groove is visible and install snap ring (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Removal > Page 9912 8. Install stub shaft yoke (1) on U-joint cross (2). 9. Tap fist bearing cap into the stub shaft yoke bore far enough to position cross. 10. Position receiver/socket (1) on shaft yoke and driver/socket (2) on bearing cap in press. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Removal > Page 9913 11. Press bearing cap into stub shaft yoke (1) until bearing cap snap ring groove is visible and install snap ring (2). 12. Position receiver/socket (1) on stub shaft yoke and driver/socket (2) on bearing cap in press. 13. Press bearing cap into stub shaft yoke (1) until bearing cap snap ring groove is visible and install snap ring (2). 14. Install axle shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Front Axle - C205FD Seals and Gaskets: Service and Repair Front Axle - C205FD Removal REMOVAL 1. Remove half shaft from vehicle. 2. Clean axle seal area. 3. Remove O-ring (1) and snap ring (2) from axle shaft (3). 4. Remove axle with Remove 8420A (2,3,4) and Slide Hammer C-3752. 5. Remove axle shaft seal with a seal puller. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Front Axle - C205FD > Page 9918 1. Wipe axle shaft tube bore clean. 2. Install new axle shaft seal with Installer 8694 (1). 3. Install axle shaft with new snap ring and verify axle shaft snap ring is seated in side gear. 4. Install O-ring (1) and snap ring (2) on axle shaft (3). 5. Install half shaft. 6. Verify differential fluid level and add fluid if necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Front Axle - C205FD > Page 9919 Seals and Gaskets: Service and Repair Front Axle - 9 1/4 AA Removal REMOVAL 1. Remove hub bearings and axle shafts. 2. Remove differential from differential housing (2). 3. Remove differential bearing adjusters (1). 4. Remove axle seals (2) located behind adjusters with Receiver 8498 and Extractor 6310. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Front Axle - C205FD > Page 9920 5. Install Receiver 8498 (1) into the adjuster bore. 6. Install Extractor Rod 6310 with Extractor Foot 6310-9 (2) through the receiver and axle seal. 7. Install Extractor Plate 6310-2 and Nut 6310-7 (2) on the extractor rod (1). 8. Tighten nut (2) on extractor rod (1) to pull seal into the receiver. Installation INSTALLATION 1. Install axle seal on Installer Cups 8885-2 (1) (3) and position cups with seals into the housing. NOTE: Seals are installed with the axle guide facing outward. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Front Axle - C205FD > Page 9921 2. Install Turnbuckle 8885-1(2) into installer cups and expand the turnbuckle until the seals bottom out in the housing. 3. Install adjuster (1) into the differential housing (2). 4. Install differential in housing. 5. Install axle shaft and hub bearings. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Front Axle - C205FD > Page 9922 Seals and Gaskets: Service and Repair Rear Axle - 9 1/4 Removal REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal (1) from the axle tube with a seal puller. Installation INSTALLATION 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. 2. Coat the lip of the new seal with axle lubricant and install a seal with Installer C-4076-B and Handle C-4735. NOTE: When tool contacts the axle tube, the seal is installed to the correct depth. 3. Install the axle shaft (1). 4. Install differential cover and fill with gear lubricant to the bottom of the fill plug hole. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications WHEEL BEARING LUBRICANT Mopar Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front - Independent Front Suspension Wheel Bearing: Service and Repair Front - Independent Front Suspension Removal 4X4 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper and rotor. 4. Remove the ABS wheel speed sensor if equipped. 5. Remove the halfshaft nut. NOTE: Do not strike the knuckle with a hammer to remove the tie rod end or the ball joint. Damage to the steering knuckle will occur. 6. Remove the tie rod end nut and separate the tie rod from the knuckle using remover 9360. 7. Remove the upper ball joint nut and separate the upper ball joint from the knuckle using remover 9360. 8. Pull down on the steering knuckle to separate the halfshaft (2) from the hub/bearing. 9. Remove the three hub/bearing mounting bolts (1) from the steering knuckle. 10. Slide the hub/bearing out of the steering knuckle. 11. Remove the brake dust shield. Installation 4X4 1. Install the brake dust shield (2). 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts to 163 Nm (120 ft. lbs.). 3. Install the brake rotor and caliper. 4. Install the ABS wheel speed sensor if equipped. 5. Install the upper ball joint nut to the steering knuckle and tighten to 54 Nm (40 ft. lbs.) (on 1500 series only an additional 90° turn). 6. Install the tie rod end nut to the steering knuckle and tighten to 61 Nm (45 ft. lbs.) then an additional 90°. 7. Install the halfshaft nut and tighten to 251 Nm (185 ft. lbs.). 8. Install the wheel and tire assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front - Independent Front Suspension > Page 9928 9. Remove the support and lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front - Independent Front Suspension > Page 9929 Wheel Bearing: Service and Repair Front - Link/Coil Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the hub extension (1) mounting nuts and remove the extension from the rotor if equipped. 4. Remove the brake caliper. 5. Remove the cotter pin (2) and the hub nut (1) from the axle shaft. 6. Remove the caliper adapter. 7. Remove the disc brake rotor. 8. Disconnect the wheel speed sensor wire. 9. Remove the hub/bearing 4 mounting bolts and remove the hub/bearing. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front - Independent Front Suspension > Page 9930 1. Position the brake shield (1) on bolts. 2. Install the hub/bearing to the knuckle. Tighten the hub/bearing bolts (2) to 202 Nm (149 ft. lbs.) 3. Install the hub nut and tighten to 356 Nm (263 ft. lbs.). 4. Install the wheel speed sensor to the hub. 5. Install the disc brake rotor. 6. Install the brake caliper adapter with the caliper. 7. Install the hub extension and nuts to the front rotor. Tighten nuts to 130 Nm (96 ft.lbs). HD DRW ONLY. 8. Install the wheel and tire assemblies. 9. Remove the support and lower the vehicle. 10. Apply the brakes several times to seat the brake shoes and caliper piston. Do not move the vehicle until a firm brake pedal is obtained. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Hub Nut Tighten to .............................................................................................................................. ............................................................... 356 Nm (263 ft. lbs.) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Adjustments Center Support: Adjustments BEARING CENTER Launch shudder is a vibration that occurs at first acceleration from a stop. Shudder vibration usually peaks at the engines highest torque output. Shudder is a symptom associated with vehicles using a two-piece propeller shaft. To decrease shudder, lower the center bearing in 3.0 mm (0.125 in.) increments. Use shim stock or fabricated plates. Do not use washers. Replace the original bolts with the appropriate increased length bolts. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Removal Center Support: Service and Repair Removal REMOVAL 1. Remove rear propeller shaft. 2. Make installation reference marks on rear shaft (1) and front shaft (2). 3. Remove slip joint boot (1) clamp (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Removal > Page 9941 4. Slide boot (1) off boot collar (2) and separate the two shafts. 5. Position Bearing Splitter Tool 1130 (1) between propeller shaft and center bearing (2). 6. Install Bridge 938 (3) on the splitter (1) and remove center bearing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Removal > Page 9942 Center Support: Service and Repair Installation INSTALLATION 1. Slide center bearing (1) and boot collar (2) on shaft. 2. Install boot collar (2) and center bearing (1) with Installer 6448A. 3. Clean shaft splines and apply a coat of multi-purpose grease. 4. Align master splines and slide front and rear half-shafts together. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Removal > Page 9943 5. Slide slip yoke boot (1) on boot collar (2). 6. Install slip yoke boot (1) clamp (2). 7. Install propeller shaft in vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications Drive/Propeller Shaft: Specifications PROPELLER SHAFT Torque Specifications Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 9947 Drive/Propeller Shaft: Testing and Inspection PROPELLER SHAFT PROPELLER SHAFT VIBRATION Out-of-round tires or wheels that are out of balance, will cause a low frequency vibration. Driveline vibration can also be caused by loose or damaged engine mounts. Propeller shaft vibration increases with vehicle speed. A vibration that occurs at a specific speed range, is not usually caused by an out of balance propeller shaft. Defective universal joints or an incorrect propeller shaft angle are usually the cause of such a vibration. Driveline Vibration PROPELLER SHAFT BALANCE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 9948 If propeller shaft is suspected of being out of balance, use the following procedure. NOTE: Indexing propeller shaft 180 degrees relative to the yoke may eliminate some vibrations. 1. Raise and support vehicle. 2. Clean all foreign material from the propeller shaft and universal joints. 3. Inspect propeller shaft for missing balance weights, broken welds and bent areas. If propeller shaft is bent, it must be replaced. 4. Inspect universal joints for wear and properly installed. 5. Check propeller shaft bolt torques. 6. Remove wheels and install lug nuts to retain brake rotors. 7. Mark and number the shaft six inches from the pinion yoke end at four positions 90 degrees apart. 8. Run and accelerate vehicle until vibration occurs. Note the intensity and speed the vibration occurred. Stop the engine. 9. Install a screw clamp at position (1). 10. Start engine and check vibration. If there is little or no change move the clamp to the next positions. Repeat the vibration test. NOTE: If there is no difference in vibration at this positions, the vibration may not be the propeller shaft. 11. If vibration decreased, install a second clamp (1) and repeat the test. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 9949 12. If additional clamp causes an additional vibration, separate the clamps 1/2 inch (1) above and below the mark. Repeat the vibration test. 13. Increase distance between the clamp screws (1) (2) and repeat test, until the least amount of vibration is noticed. Bend the slack end of the clamps so screws will not loosen. 14. If vibration remains unacceptable, repeat the procedure to the front end of the propeller shaft. 15. Install wheels and lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle Drive/Propeller Shaft: Service and Repair Propeller Shaft Angle PROPELLER SHAFT ANGLE ONE PIECE PROPELLER SHAFT This procedure applies to front and rear propeller shafts. NOTE: To obtain output angle (A) on the front propeller shaft equipped with a C/V joint, place inclinometer on machined surface of the C/V joint. 1. Raise vehicle and support the axles as level as possible, allowing the wheels and propeller shaft to turn. 2. Remove universal joint snap rings if equipped, so inclinometer base sits flat. 3. Rotate shaft until transmission/transfer case output yoke bearing is facing downward. NOTE: Always take measurements from front to rear and on the same side of the vehicle. 4. Place Inclinometer 7663 on yoke bearing cap or pinion flange ring parallel to the shaft. Center bubble in sight glass and record measurement (A). This measurement will give you the transmission yoke Output Angle (A). 5. Rotate propeller shaft 90 degrees and place Inclinometer on yoke bearing parallel to the shaft. Center bubble in sight glass and record measurement. This measurement can also be taken at the rear end of the shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 9952 This measurement will give you the Propeller Shaft Angle (C). 6. Rotate propeller shaft 90 degrees and place inclinometer on companion flange yoke bearing parallel to the shaft. Center bubble in sight glass and record measurement. This measurement will give you the pinion Companion Flange Input Angle (B). 7. Subtract smaller figure from larger (C minus A) to obtain Transmission/Transfer Case Output Operating Angle. 8. Subtract smaller figure from larger (C minus B) to obtain axle Input Operating Angle. Refer to rules and example for additional information. RULES - Good cancellation of U-joint operating angles should be within 1 degree. - Operating angles should be less than 3 degrees. - Operating angles less than 10 degrees for double cardan U-joint. - At least 1/2 of one degree continuous operating propeller shaft angle. TWO PIECE PROPELLER SHAFT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 9953 Two piece propeller shaft angles measurement is the same as a one-piece propeller shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 9954 Drive/Propeller Shaft: Service and Repair Lubrication LUBRICATION Vehicles with double cardan universal joint front propeller shaft (1) are equipped with a grease fitting (2). Grease the double cardan universal joint at each oil change. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 9955 Drive/Propeller Shaft: Service and Repair Propeller Shaft Front HD Removal REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Remove exhaust crossover pipe. 3. Mark a line across axle (3)/transfer case (2) companion flange and propeller shaft flange yokes for installation reference. 4. Remove axle/transfer case companion flange bolts. 5. Remove propeller shaft. Installation INSTALLATION 1. Install propeller shaft (1) with all reference marks aligned. 2. Install transfer case companion flange (2) bolts and tighten to 88 Nm (65 ft. lbs.). 3. Install new axle companion flange (3) bolts and tighten to 28 Nm (21 ft. lbs.). NOTE: Companion flange bolts incorporate a Loctite(R) patch, new bolts should be used. If bolts are not available, clean bolts and apply Loctite(R) 242 to the threads. 4. Install skid plate, if equipped. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 9956 Drive/Propeller Shaft: Service and Repair Propeller Shaft Rear HD Removal REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Mark propeller shaft (1) pinion flange (2) and propeller shaft flange (4) with installation reference marks (3). 3. If equipped with manual transmission, mark manual transmission flange (1) and propeller shaft flange (2) for installation reference. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 9957 4. If equipped with a center bearing (1) mark an outline of the center bearing on the center bearing bracket for installation reference. Then support propeller shaft and remove center bearing bolts (2). 5. Remove pinion flange (1) bolts from propeller shaft (2). 6. Slide propeller shaft back off automatic transmission/transfer case output shaft, then mark propeller shaft (1) and transmission/transfer case output shaft (2) for installation reference. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 9958 7. If equipped with manual transmission remove flange (1) bolts (2). 8. Remove propeller shaft from vehicle. CAUTION: Failure to follow these instructions may result in a driveline vibration. Installation INSTALLATION 1. Slide slip yoke (1) onto automatic transmission/transfer case output shaft (2) with reference marks aligned. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 9959 2. If equipped with manual transmission, align transmission flange (1) and propeller shaft reference marks. Install new flange bolts (2) and tighten to 115 Nm (85 ft. lbs.). 3. If two piece propeller shaft, align center bearing (1) with reference marks on center bearing bracket and tighten bolts (2) to 54 Nm (40 ft. lbs.). 4. Align reference marks on propeller shaft and pinion flange. Install new companion flange (1) bolts and tighten to 115 Nm (85 ft. lbs.) CAUTION: Failure to follow these instruction may result in a driveline vibration. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Page 9960 Drive/Propeller Shaft: Tools and Equipment PROPELLER SHAFT SPLITTER 1130 INSTALLER 6052 INSTALLER 6448A Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Page 9961 INCLINOMETER 7663 BRIDGE 938 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan Universal Joint: Service and Repair Universal Joints-Single Cardan Disassembly - With Injected Ring DISASSEMBLY - WITH INJECTED RING 1. Place shaft yoke in vise. 2. Position U-joint press (1) with receiver (2) on propeller shaft yoke. 3. Pressed U-joint bearing caps (1) out of shaft yoke (2). 4. Remove lower bearing cap from shaft yoke. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 9966 5. Turn shaft over and position press (1) with receiver (2) on shaft yoke. 6. Press remaining U-joint bearing cap out of shaft yoke. 7. Remove flange (1) with U-joint out of shaft yoke (2). 8. Position U-joint press (2) with receiver (1) on flange. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 9967 9. Press U-joint bearing caps (1) out of flange (2). 10. Remove bearing cap on the outside of the flange. 11. Position U-joint press (2) with receiver (1) on flange. 12. Press remaining U-joint bearing cap out of flange. 13. Remove U-joint from flange. Disassembly - With Snap Rings DISASSEMBLY - WITH SNAP RINGS 1. Tap outside of bearing cap with a drift to loosen snap ring. 2. Remove snap rings (1) from both sides of yoke. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 9968 3. Position yoke with the grease fitting if equipped, pointing up. 4. Position a socket (2) with a inside diameter large enough to receive the bearing cap, beneath the yoke on a press. 5. Place another socket with an outside diameter smaller than bearing cap on the upper bearing cap and press (1) the lower cap through the yoke. NOTE: If bearing cap will not pull out of the yoke after pressing, tap yoke ear near bearing cap to dislodge the cap. 6. Pull bearing cap of the yoke. 7. Turn yoke over in the press and straighten the cross (1). Press the cross until the remaining bearing cap (2) can be removed. CAUTION: If cross or bearing cap are not straight during removal, the bearing cap will score the walls of the yoke bore and damage can occur. Assembly - With Injected Ring ASSEMBLY - WITH INJECTED RING Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 9969 NOTE: Replacement joint has internal snap rings. 1. Place joint in flange with one bearing cap. 2. Position press (3) with receiver (1) on flange and bearing cap (2). 3. Press bearing cap until snap ring groove (1) is through the flange (2). 4. Install snap ring (2) on bearing (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 9970 5. Position press (3) with receiver (2) on remaining bearing cap (1) and flange. 6. Press bearing cap until snap ring groove is through the flange. 7. Install snap ring (1) on bearing cap (2). 8. Install flange (1) with U-joint in yoke (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 9971 9. Position press (2) with receiver (1) and lower bearing cap (3) on yoke. 10. Press bearing cap until snap ring groove is through the yoke. 11. Install snap ring (2) on bearing cap (1). 12. Position press (2) with receiver (3) on remaining bearing cap (1) and yoke. 13. Press remaining bearing cap until snap ring groove is through the yoke. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 9972 14. Install snap ring (2) on bearing cap (1). Assembly - With Snap Rings ASSEMBLY - WITH SNAP RINGS 1. Apply (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores. 2. Position cross (1) in yoke (2) with lube fitting pointing up, if equipped. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 9973 3. Place a bearing cap (1) over the cross end (2) and align cap with yoke bore. 4. Press bearing cap into the yoke bore enough to clear snap ring groove. 5. Repeat STEP 3 and STEP 4 to install the opposite bearing cap. NOTE: If joint is stiff or binding, strike the yoke with a soft hammer to seat the needle bearings. 6. Add grease to lube fitting, if equipped. 7. Install propeller shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 9974 Universal Joint: Service and Repair Universal Joints-Double Cardan Disassembly DISASSEMBLY 1. Remove propeller shaft. 2. Mark propeller shaft, link yoke and flange yoke for assembly reference. 3. Tap outside of the bearing cap assembly with drift to loosen snap rings. 4. Remove all bearing cap snap rings. 5. Remove grease fittings if equipped. 6. Position a socket on the press with an inside diameter large enough to receive the bearing cap under the link yoke. 7. Place another socket with an outside diameter smaller than the bearing cap on the upper bearing cap. 8. Press one bearing cap from outboard side of the link yoke, enough to grasp the cap with vise jaws. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 9975 9. Grasp protruding bearing cap with vise jaws and tap link yoke with a mallet to remove bearing cap. 10. Flip assembly and repeat STEP 6, STEP 7, STEP 8 and STEP 9 to remove the opposite bearing cap. 11. Remove cross centering kit assembly and spring. 12. Press remaining bearing caps out the other end of the link yoke. Assembly ASSEMBLY CAUTION: All alignment marks on the link yoke and propeller shaft yoke must be aligned during assembled. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 9976 1. Apply (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores. 2. Fit cross into the propeller shaft yoke. 3. Place bearing cap over the trunnion and align cap with the yoke bore. Keep needle bearings upright in the bearing cap. 4. Press bearing cap into yoke bore enough to clear snap ring groove and install snap-ring. 5. Flip propeller shaft yoke and install other bearing cap onto the opposite trunnion and install a snap ring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 9977 6. Fit link yoke onto remaining trunnions and press both bearing caps into place and install snap rings. 7. Install centering kit assembly inside the link yoke. NOTE: Verify spring is properly positioned. 8. Place two bearing caps on opposite trunnions of the remaining cross. Fit open trunnions into the link yoke bores and bearing caps into the centering kit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 9978 9. Press remaining two bearing caps into place and install snap rings. 10. Tap snap rings to seat them into the grooves. 11. Flexing the joint beyond center, the joint should snap over-center in both directions if correctly assembled. 12. Install propeller shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Technical Service Bulletins > Customer Interest for Flywheel: > 06-001-07 > Feb > 07 > M/T - Difficult Gear Engagement Flywheel: Customer Interest M/T - Difficult Gear Engagement NUMBER: 06-001-07 GROUP: Clutch DATE: February 03, 2007 SUBJECT: Clutch System May Over-Adjust Causing Difficulty Engaging Transmission Gear OVERVIEW: This bulletin involves replacement of the clutch system flywheel, pressure plate, and disc. MODELS: 2007 (DHID1IDC) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 5.9L or 6.7L Cummins turbo-diesel engine and the G56 manual transmission (sales code ETH, ETJ, and DEG respectively), and built on or before November 09, 2006 (MDH 1109XX). SYMPTOM/CONDITION: The customer may experience difficulty attempting to engage a manual transmission gear. This may be due to the self-adjusting mechanism in the clutch system. The self-adjusting clutch mechanism may over-adjust (forward adjust). This condition most often will occur within the first 1,000 miles of vehicle operation. DIAGNOSIS: 1. Inspect the clutch hydraulic system for leaks and or low fluid. 2. Is there a clutch system hydraulic leak and/or is the hydraulic fluid level low? a. If YES >> then repair the clutch hydraulic system. Proceed to the next step. b. If NO »> then proceed to the next step. 3. Evaluate the shift efforts of 1st gear when the engine is off and when the engine is running. a. With the engine off and the clutch pedal fully depressed (pushed down) attempt to shift into 1st gear. b. With the transmission in neutral, parking brake firmly set, start the engine and allow to idle. c. With the engine running, service brake fully applied, and the clutch pedal fully depressed (pushed down) attempt to shift into 1st gear. 4. When attempting to engage 1st gear, is the shift effort substantially higher (more difficult or unable to engage 1st gear) when the engine is running, than when the engine is off? a. If YES >> then perform the Repair Procedure b. If NO >> then proceed to the next step. 5. Evaluate the shift efforts of Reverse gear when the engine is off and when the engine is running. a. With the engine off and the clutch pedal fully depressed (pushed down) attempt to shift into Reverse gear. b. With the transmission in neutral, parking brake firmly set, start the engine and allow to idle. C. With the engine running, service brake fully applied, and the clutch pedal fully depressed (pushed down) attempt to shift into Reverse gear. 6. When attempting to engage Reverse gear, is the shift effort substantially higher (more difficult or unable to engage Reverse gear) when the engine is running, than when the engine is off? a. If YES »> then perform the Repair Procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Technical Service Bulletins > Customer Interest for Flywheel: > 06-001-07 > Feb > 07 > M/T - Difficult Gear Engagement > Page 9987 b. If NO »> then this Bulletin does not apply. Further diagnosis is required. PARTS REQUIRED: REPAIR PROCEDURE: NOTE:When the clutch pressure plate over-adjusts, the plate diaphragm fingers appear to be flat (collapsed) and marks on the clutch disc will be present due to contact with the collapsed plate diaphragm fingers. 1. Replace the dual mass flywheel, pressure plate, clutch disc, and plate attaching bolts. Refer to TechCONNECT for detailed service repair procedures. From TechCONNECT select: the "Service Info" tab and enter vehicle information (year, model, and engine). Select: 6 - Clutch > Flywheel and Disc - Clutch > Removal, Installation, and Adjustments. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Flywheel: > 06-001-07 > Feb > 07 > M/T - Difficult Gear Engagement Flywheel: All Technical Service Bulletins M/T - Difficult Gear Engagement NUMBER: 06-001-07 GROUP: Clutch DATE: February 03, 2007 SUBJECT: Clutch System May Over-Adjust Causing Difficulty Engaging Transmission Gear OVERVIEW: This bulletin involves replacement of the clutch system flywheel, pressure plate, and disc. MODELS: 2007 (DHID1IDC) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 5.9L or 6.7L Cummins turbo-diesel engine and the G56 manual transmission (sales code ETH, ETJ, and DEG respectively), and built on or before November 09, 2006 (MDH 1109XX). SYMPTOM/CONDITION: The customer may experience difficulty attempting to engage a manual transmission gear. This may be due to the self-adjusting mechanism in the clutch system. The self-adjusting clutch mechanism may over-adjust (forward adjust). This condition most often will occur within the first 1,000 miles of vehicle operation. DIAGNOSIS: 1. Inspect the clutch hydraulic system for leaks and or low fluid. 2. Is there a clutch system hydraulic leak and/or is the hydraulic fluid level low? a. If YES >> then repair the clutch hydraulic system. Proceed to the next step. b. If NO »> then proceed to the next step. 3. Evaluate the shift efforts of 1st gear when the engine is off and when the engine is running. a. With the engine off and the clutch pedal fully depressed (pushed down) attempt to shift into 1st gear. b. With the transmission in neutral, parking brake firmly set, start the engine and allow to idle. c. With the engine running, service brake fully applied, and the clutch pedal fully depressed (pushed down) attempt to shift into 1st gear. 4. When attempting to engage 1st gear, is the shift effort substantially higher (more difficult or unable to engage 1st gear) when the engine is running, than when the engine is off? a. If YES >> then perform the Repair Procedure b. If NO >> then proceed to the next step. 5. Evaluate the shift efforts of Reverse gear when the engine is off and when the engine is running. a. With the engine off and the clutch pedal fully depressed (pushed down) attempt to shift into Reverse gear. b. With the transmission in neutral, parking brake firmly set, start the engine and allow to idle. C. With the engine running, service brake fully applied, and the clutch pedal fully depressed (pushed down) attempt to shift into Reverse gear. 6. When attempting to engage Reverse gear, is the shift effort substantially higher (more difficult or unable to engage Reverse gear) when the engine is running, than when the engine is off? a. If YES »> then perform the Repair Procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Flywheel: > 06-001-07 > Feb > 07 > M/T - Difficult Gear Engagement > Page 9993 b. If NO »> then this Bulletin does not apply. Further diagnosis is required. PARTS REQUIRED: REPAIR PROCEDURE: NOTE:When the clutch pressure plate over-adjusts, the plate diaphragm fingers appear to be flat (collapsed) and marks on the clutch disc will be present due to contact with the collapsed plate diaphragm fingers. 1. Replace the dual mass flywheel, pressure plate, clutch disc, and plate attaching bolts. Refer to TechCONNECT for detailed service repair procedures. From TechCONNECT select: the "Service Info" tab and enter vehicle information (year, model, and engine). Select: 6 - Clutch > Flywheel and Disc - Clutch > Removal, Installation, and Adjustments. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Technical Service Bulletins > Page 9994 Flywheel: Description and Operation DESCRIPTION STANDARD FLYWHEEL The standard (3) is a heavy plate bolted to the rear of the crankshaft (1). The flywheel incorporates the ring gear (2) around the outer circumference to mesh with the starter to permit engine cranking. The rear face of the flywheel serves as the driving member to the clutch disc. DUAL MASS FLYWHEEL The Dual Mass Flywheel (1) is used on the Diesel engine with G56 transmission. The flywheel incorporates the ring gear around the outer circumference to mesh with the starter to permit engine cranking. The primary flywheel side is bolted to an adapter plate which is bolted to the crankshaft. The secondary flywheel side (2) serves as the driving member to the clutch disc. Internal springs (3) are used to dampen energy. The Dual Mass Flywheel is serviced as an assembly only and should never be taken apart. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Technical Service Bulletins > Page 9995 Flywheel: Testing and Inspection FLYWHEEL Check flywheel (3) runout whenever misalignment is suspected. Flywheel runout should not exceed 0.08 mm (0.003 in.). Measure runout at the outer edge of the flywheel face with a dial indicator. Mount the indicator on a stud installed in place of one of the flywheel bolts. Common causes of runout are: - heat warpage - improper machining - incorrect bolt tightening - improper seating on crankshaft flange shoulder - foreign material on crankshaft flange Flywheel machining is not recommended. The flywheel clutch surface is machined to a unique contour and machining will negate this feature. Minor flywheel scoring can be cleaned up by hand with 180 grit emery or with surface grinding equipment. Remove only enough material to reduce scoring (approximately 0.001 - 0.003 in.). Heavy stock removal is not recommended. Replace the flywheel if scoring is severe and deeper than 0.076 mm (0.003 in.). Excessive stock removal can result in flywheel cracking or warpage after installation; it can also weaken the flywheel and interfere with proper clutch release. Clean the crankshaft flange before mounting the flywheel. Dirt and grease on the flange surface may cock the flywheel causing excessive runout. Use new bolts when remounting a flywheel and secure the bolts with Mopar(R) Lock And Seal or equivalent. Tighten flywheel bolts to specified torque only. Overtightening can distort the flywheel hub causing runout. On a Dual Mass Flywheel (1) inspect all springs (2) for damage. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Removal Flywheel: Service and Repair Removal REMOVAL 1. Remove the transmission. NOTE: Vehicles with Dual Mass Flywheel use an adapter plate between the flywheel and crank. This plate does not need to be removed. 2. Remove the dust cover bolts (1) and the dust cover (2). 3. Using the access hole, remove each flexplate-to-flywheel bolt (1). Use Barring Tool 7471B to rotate the engine and flywheel. 4. Remove the assembly place the flywheel (1) , clutch disc (2) , and pressure plate (3) assembly on a workbench. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Removal > Page 9998 5. Loosen pressure plate bolts (1-8) evenly, a few threads at a time and in a diagonal pattern to prevent warping the plate. 6. Remove the eight pressure plate bolts (1-8) completely and remove pressure plate and disc. 7. Remove the flywheel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Removal > Page 9999 Flywheel: Service and Repair Installation INSTALLATION 1. Install flywheel on the crankshaft or adapter plate if vehicle has Dual Mass flywheel. 2. Install flywheel bolts and tighten evenly in sequence to 95 Nm (70 ft. lbs.). Vehicles with Dual Mass Flywheel, tighten adapter plate bolts to 55 Nm (40 ft. lbs.). 3. Install clutch. 4. Install transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator Overdrive Indicator Lamp: Description and Operation Overdrive Off Indicator Description DESCRIPTION An overdrive off indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The overdrive off indicator consists of a stencil-like cutout of the text O/D OFF in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the overdrive off indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The overdrive off indicator is serviced as a unit with the instrument cluster. Operation OPERATION The overdrive off indicator gives an indication to the vehicle operator when the overdrive-OFF position of the tow/haul switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The overdrive off indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the overdrive off indicator for the following reasons: - Overdrive Off Indicator Lamp-On Message - Each time the cluster receives an electronic overdrive off indicator lamp-ON message from the PCM indicating that the overdrive-OFF position of the tow/haul switch has been selected, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the overdrive off indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the overdrive off indicator or the instrument cluster circuitry that controls the indicator, refer to Instrument Cluster/Carrier Testing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 10006 For proper diagnosis of the transmission control system, the PCM, the EMIC, the CAN data bus or the electronic communication related to overdrive off indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 10007 Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator Description DESCRIPTION A tow/haul indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The tow/haul indicator consists of a stencil-like cutout of the text TOW/HAUL in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the tow/haul indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The tow/haul indicator is serviced as a unit with the instrument cluster. Operation OPERATION The tow/haul indicator gives an indication to the vehicle operator when the tow/haul function of the tow/haul switch has been selected, revising the shift schedule of the electronically controlled automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The tow/haul indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the tow/haul indicator for the following reasons: - Tow/Haul Indicator Lamp-On Message - Each time the cluster receives an electronic tow/haul indicator lamp-ON message from the PCM indicating that the tow/haul shift schedule has been selected, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the tow/haul indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the tow/haul indicator or the instrument cluster circuitry that controls the indicator refer to Instrument Cluster / Carrier testing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 10008 For proper diagnosis of the transmission control system, the PCM, the EMIC, the CAN data bus or the electronic communication related to tow/haul indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description Temperature Warning Indicator - A/T: Description and Operation Description DESCRIPTION A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The transmission over-temperature indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Transmission Temperature in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The transmission over-temperature indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description > Page 10013 Temperature Warning Indicator - A/T: Description and Operation Operation OPERATION The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received over the Controller Area Network (CAN) data bus from the Powertrain Control Module (PCM). The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Indicator Lamp-On Message - Each time the cluster receives an electronic trans over-temp indicator lamp-ON message from the PCM indicating that the transmission fluid temperature is 135° C (275° F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the indicator is cycled OFF and then ON again by the appropriate lamp-ON and lamp-OFF messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the transmission over-temperature indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the instrument cluster illuminates the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission or the transmission cooling system are being overloaded, or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED,refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transmission temperature sensor, the PCM, the EMIC, the CAN data bus or the electronic communication related to transmission over-temperature indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description Four Wheel Drive Indicator Lamp: Description and Operation Description 4WD Auto Indicator 4WD AUTO INDICATOR A 4WD auto indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD auto indicator is located on the right side of the instrument cluster, to the right of the oil pressure gauge. The 4WD auto indicator consists of a stencil-like cutout of the text 4WD AUTO in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD auto indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD auto indicator is serviced as a unit with the instrument cluster. 4WD Indicator 4WD INDICATOR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 10019 A 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional four-wheel drive system, this indicator is electronically disabled. The 4WD indicator is located on the right side of the instrument cluster, to the right of the oil pressure gauge. The 4WD indicator consists of a stencil-like cutout of the text 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD indicator is serviced as a unit with the instrument cluster. 4WD Low Indicator 4WD LOW INDICATOR A 4WD low indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD low indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The 4WD low indicator consists of a stencil-like cutout of the text 4WD LOW in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD low indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD low indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 10020 Four Wheel Drive Indicator Lamp: Description and Operation Operation 4WD Auto Indicator 4WD AUTO INDICATOR The 4WD auto indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD auto mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD auto indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD auto indicator for the following reasons: - 4WD Auto Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD auto indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD auto indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD auto mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD auto indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD auto indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. 4WD Indicator 4WD INDICATOR The 4WD indicator gives an indication to the vehicle operator when the transfer case has been shifted into a 4WD mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD indicator for the following reasons: - 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly or the manual transfer case through the transfer case switch to determine when the 4WD mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the transfer case switch, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. 4WD Low Indicator 4WD LOW INDICATOR The 4WD low indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD low mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD low indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 10021 indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD low indicator for the following reasons: - 4WD Low Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD low indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD low indicator will be turned ON, then OFF again during the LED portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD low mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD low indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD low indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Description Malfunction Indicator Lamp - Transfer Case: Description and Operation Description DESCRIPTION A service 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The service 4WD indicator consists of a stencil-like cutout of the text SVC 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The service 4WD indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Description > Page 10026 Malfunction Indicator Lamp - Transfer Case: Description and Operation Operation OPERATION The service 4WD indicator gives an indication to the vehicle operator when the Totally Integrated Power Module (TIPM) has recorded a Diagnostic Trouble Code (DTC) for an electronic transfer case circuit or component malfunction. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the TIPM over the Controller Area Network (CAN) data bus. The service 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the service 4WD indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the service 4WD indicator is illuminated for about two seconds as a bulb test. - Service 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic service 4WD indicator lamp-ON message from the TIPM, the service 4WD indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the TIPM for 10 seconds the service 4WD indicator is illuminated by the cluster to indicate a loss of TIPM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the TIPM. - Actuator Test - Each time the cluster is put through the actuator test, the service 4WD indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case control circuits and transfer case shift motor/mode sensor assembly to determine the condition of the system. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the service 4WD indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the TIPM, the EMIC, the CAN data bus or the electronic communication related to service 4WD indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 10033 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 10038 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications MANUAL TRANSMISSION FLUID CAPACITY Diesel Engine - G56 ............................................................................................................................ .............................................................. 5.6 L (3.4 Pt) 5.7 L Engine - G56 .............................................................................................................................. .............................................................. 4.7 L (10 Pt) Getrag 238 ........................................................................................................................................... ............................................................. 2.2 L (4.6 Pt) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 10041 Fluid - M/T: Fluid Type Specifications NOTE: DaimlerChrysler recommends using Mopar lubricants or lubricants of equal quality. MANUAL TRANSMISSION LUBRICANT G56 ...................................................................................................................................................... ........................... Mopar ATF +4 Transmission Fluid Getrag 238 ....................................................... ............................................................................................................... Mopar ATF +4 Transmission Fluid Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection SWITCH-CLUTCH PEDAL POSITION 1. Disconnect switch 2-wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed - Continuity - Pedal Released - No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Power Take-Off Switch > Component Information > Description and Operation > Description Power Take-Off Switch: Description and Operation Description DESCRIPTION This Engine Control Module (ECM) input is used only on models equipped with aftermarket Power Take Off (PTO) units. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Power Take-Off Switch > Component Information > Description and Operation > Description > Page 10051 Power Take-Off Switch: Description and Operation Operation OPERATION This input is used only to tell the ECM that the aftermarket PTO (Power Take Off) unit has been engaged. The ECM will disable (temporarily shut down) certain OBD II diagnostic trouble codes when the PTO unit is engaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Description and Operation > Description Power Take-Off Switch: Description and Operation Description DESCRIPTION This Engine Control Module (ECM) input is used only on models equipped with aftermarket Power Take Off (PTO) units. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Description and Operation > Description > Page 10057 Power Take-Off Switch: Description and Operation Operation OPERATION This input is used only to tell the ECM that the aftermarket PTO (Power Take Off) unit has been engaged. The ECM will disable (temporarily shut down) certain OBD II diagnostic trouble codes when the PTO unit is engaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set Control Module: Customer Interest Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 10068 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 10069 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: Customer Interest A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 10074 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 10075 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set Control Module: Customer Interest A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 10080 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 10081 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 10082 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 10083 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set Control Module: All Technical Service Bulletins Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 10089 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 10090 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: All Technical Service Bulletins A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 10095 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 10096 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set Control Module: All Technical Service Bulletins A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 10101 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 10102 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 10103 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 10104 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10105 Control Module: Locations Component ID: 214 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2-3 POWER TAKEOFF RELAY ENABLE K427 18OR/LG 4-5 PRESSURE SIGNAL 4 T803 20DG/BR 6 PRESSURE SIGNAL 1 T800 20DG/BR 7-8-9-10 - 11 PRESSURE SIGNAL 5 T804 20YL/DB 12 PRESSURE SIGNAL 3 T802 20DG/PK 13 - 14 - 15 - 16 PRESSURE SIGNAL 6 T805 20DG/OR 17 PRESSURE SIGNAL 2 T801 20DG/RD Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10106 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Description Circuit 1 8 VOLT SUPPLY T72 20YL/DB 2 OUTPUT SPEED SIGNAL T14 20DG/BR 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10107 5-6-7 FUSED B(+) A104 20YL/RD 8 GROUND Z133 18BK/LG 9-10 - 11 - 12 - 13 - 14 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 15 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 16 TCC TEMPERATURE SIGNAL T819 20YL/VT 17 GROUND Z133 18BK/LG 18 - 19 SHIFT 4 CONTROL T811 20DG/LB 20 CAN C BUS (+) D65 20WT/LG 21 CAN C BUS (-) D64 20WT/LB 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10108 Pin Description Circuit 1 SHIFT 1 CONTROL T808 20DG/GY 2-3 SHIFT 3 CONTROL T810 20DG/DB 4-5 LINEAR 3 CONTROL T817 20YL/BR 6 LINEAR 1 GROUND T812 20DG/TN 7 LINEAR 1 CONTROL T813 20DG/LG 8 LINEAR 2 CONTROL T815 20YL/RD 9 LINEAR 2 GROUND T814 20YL/BR 10 PRESSURE SIGNAL 7 T806 20DG/VT 11 - 12 - 13 - 14 - - 15 LINEAR 3 GROUND T816 20YL/PK 16 TRS 1 SIGNAL T828 20DG/DB 17 TRS T42 SIGNAL T42 20DG/YL 18 TRS T3 SIGNAL T3 20DG/DB 19 TRS DRIVE SIGNAL T827 20DG/LB 20 TRS PARK SIGNAL T824 20YL/DB 21 TRS REVERSE SIGNAL T826 20DG/DB 22 SHIFT 2 CONTROL T809 20DG/YL 23 - 24 - 25 - 26 PRESSURE SIGNAL 8 T807 20DG/WT 27 - 28 TEMPERATURE SENSOR GROUND T820 20YL/WT 29 TRS NEUTRAL SIGNAL T825 20DG/YL 30 LINEAR 4 CONTROL T821 20YL/GY 31 LINEAR 4 GROUND T818 20YL/OR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10109 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10110 Control Module: Diagrams Component ID: 214 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2-3 POWER TAKEOFF RELAY ENABLE K427 18OR/LG 4-5 PRESSURE SIGNAL 4 T803 20DG/BR 6 PRESSURE SIGNAL 1 T800 20DG/BR 7-8-9-10 - 11 PRESSURE SIGNAL 5 T804 20YL/DB 12 PRESSURE SIGNAL 3 T802 20DG/PK 13 - 14 - 15 - 16 PRESSURE SIGNAL 6 T805 20DG/OR 17 PRESSURE SIGNAL 2 T801 20DG/RD Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10111 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Description Circuit 1 8 VOLT SUPPLY T72 20YL/DB 2 OUTPUT SPEED SIGNAL T14 20DG/BR 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10112 5-6-7 FUSED B(+) A104 20YL/RD 8 GROUND Z133 18BK/LG 9-10 - 11 - 12 - 13 - 14 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 15 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 16 TCC TEMPERATURE SIGNAL T819 20YL/VT 17 GROUND Z133 18BK/LG 18 - 19 SHIFT 4 CONTROL T811 20DG/LB 20 CAN C BUS (+) D65 20WT/LG 21 CAN C BUS (-) D64 20WT/LB 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10113 Pin Description Circuit 1 SHIFT 1 CONTROL T808 20DG/GY 2-3 SHIFT 3 CONTROL T810 20DG/DB 4-5 LINEAR 3 CONTROL T817 20YL/BR 6 LINEAR 1 GROUND T812 20DG/TN 7 LINEAR 1 CONTROL T813 20DG/LG 8 LINEAR 2 CONTROL T815 20YL/RD 9 LINEAR 2 GROUND T814 20YL/BR 10 PRESSURE SIGNAL 7 T806 20DG/VT 11 - 12 - 13 - 14 - - 15 LINEAR 3 GROUND T816 20YL/PK 16 TRS 1 SIGNAL T828 20DG/DB 17 TRS T42 SIGNAL T42 20DG/YL 18 TRS T3 SIGNAL T3 20DG/DB 19 TRS DRIVE SIGNAL T827 20DG/LB 20 TRS PARK SIGNAL T824 20YL/DB 21 TRS REVERSE SIGNAL T826 20DG/DB 22 SHIFT 2 CONTROL T809 20DG/YL 23 - 24 - 25 - 26 PRESSURE SIGNAL 8 T807 20DG/WT 27 - 28 TEMPERATURE SENSOR GROUND T820 20YL/WT 29 TRS NEUTRAL SIGNAL T825 20DG/YL 30 LINEAR 4 CONTROL T821 20YL/GY 31 LINEAR 4 GROUND T818 20YL/OR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10114 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description Control Module: Description and Operation Description DESCRIPTION On gasoline vehicles the Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). 68RFE TCM LOCATION Vehicles equipped 68RFE transmission and a 6.7L Diesel engine, the TCM is housed in the NGC4 controller utilizing only the C1 and C4 connectors (TCM only). The controller is located at the rear of the engine compartment, near the right inner fender. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 10117 AS68RC TCM LOCATION On Cab Chassis models equipped with the AS68RC transmission the Transmission Control Module (TCM) has three electrical connectors and is located in the passenger compartment underneath of the left side of the dash panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 10118 Control Module: Description and Operation Operation OPERATION RLE and RFE TRANSMISSIONS The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) (if equipped) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 10119 An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 10120 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 10121 SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 10122 AISIN AS68RC TRANSMISSION The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Speed Sensor - Output Speed Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 10123 - Manifold Pressure - Throttle position - Torque Reduction Confirmation - Engine Coolant Temperature - Exhaust Brake Status (if equipped) - PTO Request (if equipped) - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Exhaust Brake Cut Request (if equipped). - Solenoids. - Torque Reduction Request. Some examples of TCM .indirect outputs are: - Transmission Temperature (to PCM). - PRNDL Position (to cluster/CCN). - PTO Status. In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI). - Storing and selecting appropriate Shift Schedules. - System self-diagnostics. - Diagnostic capabilities (with scan tool). Clutch filling time is continuously maintained when the vehicle is running. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10128 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10129 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10130 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10131 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10132 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10133 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10134 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10135 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10136 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10137 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10138 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10139 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10140 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10141 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10142 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10143 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10144 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10145 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10146 Transmission Control System Relay: Connector Views Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > AS68RC Automatic Transmission Transmission Control System Relay: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION AS68RC Automatic Transmission NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. The relay is supplied fused B+ voltage, energized by the TIPM, and is used to supply power to the TCM when the transmission is in normal operating mode. Operation OPERATION The TIPM energizes the transmission control relay. When the relay is "off", no power is supplied to the TCM and the transmission will not operate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Control Module: Locations Component ID: 204 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 LOCKER SENSOR SUPPLY T521 20YL/BK A2 LOCKER SWITCH SUPPLY T537 20YL/LG A3 LOCKER SENSOR SUPPLY T523 20YL/BK A4 - A5 - A6 CAN C BUS (+) D65 20WT/LG A7 CAN C BUS (-) D64 20WT/LB A8 REAR LOCKER SENSOR SENSE T527 20YL/TN A9 FRONT LOCKER SENSOR SENSE T522 20YL/LB A10 LOCKER SWITCH SENSE T535 20YL/BR A11 - A12 - A13 - A14 - B FUSED B(+) A121 14RD/YL B1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG B2 SWITCH SUPPLY T536 20YL/WT B3 - B4 - B5 STABILIZER BAR SWITCH SENSE T531 20YL/TN B6 LOCKER OPEN ILLUMINATION SENSE T532 20YL/GY B7 LOCKER REAR ILLUMINATION SENSE T533 20YL/LB B8 LOCKER FR/RR ILLUMINATION SENSE T534 20YL B9 STABILIZER BAR DISENGAGE ILLUMINATION SENSE T530 20YL/DG B10 STABILIZER BAR ENGAGE ILLUMINATION SENSE T529 20YL/LG B11 - B12 - B13 - B14 - C FRONT LOCKER SOURCE T520 16YL/OR C1 - C2 - C3 - C4 - C5 - - Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 10153 C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - D REAR LOCKER SOURCE T526 16YL/WT E GROUND Z935 16BK F GROUND Z935 16BK G FRONT LOCKER RETURN T524 16YL/LG H REAR LOCKER RETURN T528 16YL/GY Component Location - 29 Component Location - 28 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 10154 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 10155 Control Module: Diagrams Component ID: 204 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 LOCKER SENSOR SUPPLY T521 20YL/BK A2 LOCKER SWITCH SUPPLY T537 20YL/LG A3 LOCKER SENSOR SUPPLY T523 20YL/BK A4 - A5 - A6 CAN C BUS (+) D65 20WT/LG A7 CAN C BUS (-) D64 20WT/LB A8 REAR LOCKER SENSOR SENSE T527 20YL/TN A9 FRONT LOCKER SENSOR SENSE T522 20YL/LB A10 LOCKER SWITCH SENSE T535 20YL/BR A11 - A12 - A13 - A14 - B FUSED B(+) A121 14RD/YL B1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG B2 SWITCH SUPPLY T536 20YL/WT B3 - B4 - B5 STABILIZER BAR SWITCH SENSE T531 20YL/TN B6 LOCKER OPEN ILLUMINATION SENSE T532 20YL/GY B7 LOCKER REAR ILLUMINATION SENSE T533 20YL/LB B8 LOCKER FR/RR ILLUMINATION SENSE T534 20YL B9 STABILIZER BAR DISENGAGE ILLUMINATION SENSE T530 20YL/DG B10 STABILIZER BAR ENGAGE ILLUMINATION SENSE T529 20YL/LG B11 - B12 - B13 - B14 - C FRONT LOCKER SOURCE T520 16YL/OR C1 - C2 - C3 - C4 - C5 - - Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 10156 C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - D REAR LOCKER SOURCE T526 16YL/WT E GROUND Z935 16BK F GROUND Z935 16BK G FRONT LOCKER RETURN T524 16YL/LG H REAR LOCKER RETURN T528 16YL/GY Component Location - 29 Component Location - 28 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 10157 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description Control Module: Description and Operation Description DESCRIPTION The Transfer Case Control Module (TCCM) functionality now resides in the Totally Integrated Power Module (TIPM), refer to the TIPM information for location. The TIPM controls the 4X4 transfer case shift functions via the actuation of a shift motor and utilizing the feedback of a mode sensor assembly. Communication is via the CAN bus. Inputs include user selectable 4X4 modes that include 2WD, AWD, 4HI, 4LO, and Neutral (selections vary with the specific transfer case). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 10160 Control Module: Description and Operation Operation OPERATION The Transfer Case Control Module (TCCM) functionality in the Totally Integrated Power Module (TIPM) utilizes the input from the transfer case mounted mode sensor, the instrument panel mounted selector switch, and the following information from the vehicle's CAN bus to determine if a shift is allowed. - Engine RPM and Vehicle Speed - Diagnostic Requests - Manual Transmission and Brake Applied - PRNDL - Ignition Status - ABS Messages Once the TIP determines that a requested shift is allowed, it actuates the bi-directional shift motor as necessary to achieve the desired transfer case operating mode. The TIPM also monitors the mode sensor while controlling the shift motor to determine the status of the shift attempt. Several items can cause the requested shift not to be completed. If the TIPM has recognized a fault (DTC) of some variety, it will begin operation in one of four Functionality Levels. These levels are: - Level Zero - Normal Operation. - Level One - Only Mode Shifts Are Allowed. - Level Two - Only Mode Shifts and Shifts Into LOW Are Allowed (No Neutral Shifts Are Allowed). - Level Three - No Shifts Are Allowed The TIPM can also be operating in one of three possible power modes. These power modes are: - Full Power Mode is the normal operational mode of the module. This mode is achieved by normal CAN bus traffic being present and the ignition being in the RUN position. Reduced Power Mode will be entered when the ignition has been powered off. In this state, the module will shut down power supplied to external devices, and to electronic interface inputs and outputs. From this state the module can enter either Sleep Mode or Full Power Mode. To enter this mode, the module must receive an ignition message denoting that the ignition is off, or not receive any messages for 5 ± 0.5 seconds. To exit this mode, the module must receive one ignition message that denotes that the ignition is in the RUN position. - Sleep Mode will be entered, from the Reduced Power Mode, when no CAN traffic has been sensed for 20 ± 1 seconds. If during Sleep Mode the module detects CAN bus traffic, it will revert to the Reduced Power mode while monitoring for ignition messages. It will remain in this state as long as there is traffic other than run or start messages, and will return to Sleep mode if the bus goes without traffic for 20 ± 1 seconds. SHIFT REQUIREMENTS If the TIPM is in full power mode and at functionality level zero, it uses the following criteria to determine if a shift is allowed. If any of the driver controllable conditions are not met once the shift request is recognized, the TIPM will solidly illuminate the source position's LED and flash the desired position's LED for all shifts except NEUTRAL. The NEUTRAL shift LED strategy will be discussed later. Mode shifts will be allowed regardless of transmission gear or vehicle speed, whenever the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - A change in the Selector switch state indicates that a mode shift has been requested. - A valid mode sensor signal is being sensed by the TIPM. - Proper transmit/receive messages are occurring on the CAN bus. - Ignition key switch is in the RUN position. Range shifts will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - A change in the Selector Switch state indicating a range shift has been requested. - Transmission in NEUTRAL signal must be recognized for at least 1.5 seconds ± 100 msec. (Automatic transmissions only) - Proper transmit/receive messages are occurring on the CAN bus. - Clutch signal is recognized for 500 msec ± 50 msec (Manual transmissions only). - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position. - A valid mode sensor signal is being sensed by the TIPM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 10161 A shift into transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 4.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus. (Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the CAN bus. - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position, engine off. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TIPM. A shift out of transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 1.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus.(Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the CAN bus. - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TIPM. SHIFT SEQUENCES Once all the driver controllable conditions for the requested shift have been met, the TIPM begins a shift timer with a maximum duration of 1 second per 'D' channel transition. If the shift timer expires before the TIPM recognizes to correct mode sensor code, the shift is considered to have been blocked. The blocked shift will increment the blocked shift counter by one. The TIPM strategy for handling blocked shifts will be described later. The process the TIPM performs for the various shifts will be described first. RANGE AND MODE SHIFTS The process for performing all the range and mode shifts are the same. The following steps describe the process. - Allow time for Selector Switch debounce; 250 msec ± 50 msec. - Extinguish the source gear's LED while flashing desired transfer case position's LED. - Engage the shift motor for a maximum of 1 second ± 100 msec per 'D' channel transition in the destination gear's direction while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Solidly illuminate the selected gear's LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds ± 100 msec. per 'D' channel. The TIPM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. The exception to the preceding sequence is when a shift from 4L to 2WD/AWD is requested. If 2WD/AWD is requested from the 4L position, the transfer case is first driven to the 4H position. If the 4H position is reached, the transfer case is then driven back to the 2WD/AWD position and the shift is considered complete. If the transfer case does not reach any the 4H position, but is in the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is also considered complete. SHIFT OUT OF NEUTRAL The following steps describe the process for a shift out of NEUTRAL. - Extinguish the Neutral LED. - Engage the shift motor for a maximum of 1 second ± 100 msec toward the transfer case 4H mode position while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Extinguish the Neutral LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds 100 msec. The Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 10162 TIPM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. - When the Neutral button is released, if the 4H position is the desired position, the shift is complete. Illuminate the 4H LED. - Otherwise when the Neutral button is released, if all of the shift requirements are being met then engage the shift motor towards the desired position for 1 second ± 100 msec per 'D' channel. (if requirements for shifting are not met, illuminate the 4H LED and flash the destination LED as an indication to the driver that all of the driver controllable shift conditions are not being met). If this requires another range or mode shift, begin the range/mode shift process. - If the desired mode sensor code is not received after the shift timer expires (i.e. a blocked or other condition exists), refer to Blocked Shift Strategy. BLOCKED SHIFT STRATEGY When a shift is commanded, the shift motor will be driven towards its destination position, except in the case of shifting out of Neutral if 4L was selected (the transfer case will shift to the 4H position first, before proceeding to 4L). If the shift is blocked on the way to the destination, the TIPM may attempt to drive the motor back to the original position. This process will be allowed to occur 5 times. If the transfer case has reached a non-NEUTRAL 'D' channel during the shift re-attempts, the LED for the achieved gear position is illuminated and the shift attempts are stopped. To re-attempt the desired shift, the selector switch will need to be rotated to the current position until the switch debounce timer expires then a shift will need to be requested again. At the end of the 5th blocked attempt, the shift motor is driven towards the last known 'D' channel position. If this motor drive allows the transfer case to reach the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is considered complete and the shift attempts are ended. If the mode sensor is in the NEUTRAL region at the expiration of the shift timer, the TIPM will continue to make the shift attempts according to the blocked shift strategy independent of whether or not the driver controlled conditions are met. For shifts from NEUTRAL, if all 5 attempts fail to reach the desired position (which by default is 4H), the motor will be driven to stall in the direction of 4H or 4L, depending on the achieved position. If the transfer case has reached the 2WD/AWD or 4L between gear position nearest the NEUTRAL positions and the shift conditions are no longer being met, the transfer case will be driven toward the corresponding 'D' channel. Otherwise, the transfer case will be driven in the direction opposite the last attempt with the desired target being 4H or 4L. If the transfer case reaches the 2WD/AWD 'D' channel when being driven in the 4H direction, then one final 1.0 second drive toward 4H is attempted. If the transfer case then reaches any of the 4H positions, the shift is considered complete and the 4H LED is illuminated. If the transfer case is still the 2WD/AWD position, the shift is considered complete and the 2WD/AWD LED is illuminated. NOTE: If after the 5th blocked shift and reversal attempt, if the transfer case position is in the NEUTRAL region, shift attempts will continue until a non-NEUTRAL 'D' channel is reached. SHIFT REVERSAL TARGETS If the shift timer expires (1 second per 'D' channel) and the transfer case has not reached the desired position, all shifts will attempt to return to their original position with the exceptions of: - If the intended shift is going to the High rail from Low and can't make it, but it can make the 2WD/AWD position, the motor stops at that position. The TIPM will not attempt to cross back over NEUTRAL if it does not have to. This means that there was a block on the first attempt to go to 4H and the transfer case has made it through NEUTRAL to a known good position, then the motor will go back only to the 2WD/4WD position and execute the remainder of the attempts from there. - For shifts out of NEUTRAL, any time a shift is commanded out of NEUTRAL, the system needs to get out. The TIPM should never go to NEUTRAL unless the driver is commanding it and all required conditions are being met ENCODER DRIFT CORRECTION Whenever a shift is completed, the TIPM stores the position in memory as the transfer case's intended position. The TIPM continuously monitors the mode sensor and if the mode sensor drifts toward into a NEUTRAL region sensor position for 2.0 seconds, the TIPM will perform a motor drive to correct the drift. The transfer case will be driven toward the intended position for 1.0 seconds ± 100 msec. The TIPM will wait for 2.0 seconds ± 50 msec. and repeat the attempt to shift to the desired position. This will continue until the intended position is reached. SHIFT MOTOR BRAKING Two modes of shift motor braking are employed to improve shift performance, static and dynamic. Static shift motor braking is utilized under the following conditions: - Whenever the transfer case is in the 2WD/AWD or 4L 'D' channel position. - Whenever an invalid mode sensor code is present. Static motor braking is achieved by applying +12V on both shift motor wires. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 10163 NOTE: Static Shift Motor Braking is independent of ignition key position. SHIFT ATTEMPT LIMIT To protect the transfer case system, the TIPM will impose a limit on the number of shifts that can occur over a calibrated time period. The system will monitor the number of 'D' channel segment transitions that occur in any 30 second time period. If the number of segment transitions is 30 or greater, the system will go into a default mode. The default mode of operation for shifting is that the number of allowed 'D' channel transitions permitted to occur will be 3 over each 15 second ± 100 msec calibrated window of time. After 5 minutes ± 100 msec, the motor can be assumed to have cooled down and the system will revert to normal operation. The following rules also apply to the shift limit: - The attempt limit will not prevent shifts coming out of NEUTRAL, they will be allowed regardless of the counter/timer. - Any shift that is in progress when the counter reaches a maximum count in time will be allowed to complete before the default mode is entered. D-channel transitions during this period will not be counted towards the default mode limit. - A block, regardless of the direction, whether towards destination or back towards reversal target (shift timer expiring), will count as a value of 2 transitions towards the 30 segment transitions to go into default mode as defined above. Current attempt limit values are 30 transitions in 30 seconds and default mode values are 3 transitions every 15 seconds for 5 minutes. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Component ID: 410 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Description Circuit 1 SENSOR GROUND T160 20DG/WT Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 5 VOLT SUPPLY F856 20YL/PK 3 LINE PRESSURE SIGNAL T38 20YL/BR 4-- Component Location - 23 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 10169 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 10170 Fluid Pressure Sensor/Switch: Diagrams Component ID: 410 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Description Circuit 1 SENSOR GROUND T160 20DG/WT Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 5 VOLT SUPPLY F856 20YL/PK 3 LINE PRESSURE SIGNAL T38 20YL/BR 4-- Component Location - 23 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 10171 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description Fluid Pressure Sensor/Switch: Description and Operation Description DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, which is part of the pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the pump inlet. The system contains a Line Pressure Sensor, which is a direct input to the TCM. The line pressure sensor monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description > Page 10174 Fluid Pressure Sensor/Switch: Description and Operation Operation OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts, to ensure consistent shift quality. During all other operation, the desired line pressure value is adjusted based on torque level and other transmission requirements. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal Fluid Pressure Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal > Page 10177 Fluid Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Overdrive Switch: Locations Component ID: 490 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Description Circuit 123 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 4 GROUND Z71 20LB/BK 5 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 6 SENSOR GROUND T160 20DG/WT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 10181 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 10182 Overdrive Switch: Diagrams Component ID: 490 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Description Circuit 123 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 4 GROUND Z71 20LB/BK 5 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 6 SENSOR GROUND T160 20DG/WT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 10183 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 10184 Overdrive Switch: Testing and Inspection DIAGNOSIS AND TESTING - OVERDRIVE ELECTRICAL CONTROLS The tow/haul overdrive off switch, valve body solenoid, case connectors and related wiring can all be tested with a 12 volt test lamp or a volt/ohmmeter. Check continuity of each component when diagnosis indicates this is necessary. Switch and solenoid continuity should be checked whenever the transmission fails to shift into fourth gear range. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Switch: Service and Repair 42RLE Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 10187 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 10188 Overdrive Switch: Service and Repair 545RFE Automatic Transmission Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 10189 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 10190 Overdrive Switch: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 10191 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 10192 Overdrive Switch: Service and Repair AS68RC Automatic Transmission Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 10193 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 10198 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 10199 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 10200 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 10201 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 10202 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 10203 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 10204 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 10205 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 10206 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 10207 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 10208 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 10211 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 10212 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 10213 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 10214 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 10215 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 10216 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 10217 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 10218 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 10219 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 10220 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 10221 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 10224 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 10225 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 10226 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 10227 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 10228 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 10231 TRS REMOVAL/INSTALLATION 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 10232 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 10233 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 10234 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 10235 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed Transmission Speed Sensor: Locations Sensor-Input Speed Component ID: 405 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 10240 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 10241 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 10242 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 10243 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 10244 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 10245 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 10246 Transmission Speed Sensor: Locations Sensor-Output Speed Component ID: 415 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 10247 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 10248 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 10249 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 10250 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 18DG/BR 2 SPEED SENSOR GROUND T13 18DG/VT Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 10251 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 10252 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 10253 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 10254 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 10255 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 10256 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 10257 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 10258 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed Transmission Speed Sensor: Diagrams Sensor-Input Speed Component ID: 405 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 10261 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 10262 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 10263 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 10264 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 10265 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 10266 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 10267 Transmission Speed Sensor: Diagrams Sensor-Output Speed Component ID: 415 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 10268 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 10269 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 10270 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 10271 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 18DG/BR 2 SPEED SENSOR GROUND T13 18DG/VT Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 10272 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 10273 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 10274 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 10275 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 10276 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 10277 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 10278 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 10279 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Speed Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The speed sensor (1) is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Operation OPERATION Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. Signals from this sensor are shared with the powertrain control module. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 10282 Transmission Speed Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 10283 Transmission Speed Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION INPUT AND OUTPUT SPEED SENSORS The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate DC square wave signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the "teeth" of the gear pass by the sensor coil, an DC square wave is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an DC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Transmission Speed Sensor: Service and Repair 68RFE Automatic Transmission Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the transmission case. Installation INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 10286 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. Installation INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 10287 Transmission Speed Sensor: Service and Repair AS68RC Automatic Transmission Output Speed Sensor OUTPUT SPEED SENSOR OUTPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor. 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. Input Speed Sensor INPUT SPEED SENSOR INPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 10288 3. Remove the wiring connector from the input speed sensor. 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. Output Speed Sensor OUTPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. OUTPUT SPEED SENSOR 1. Lubricate the output speed sensor O-ring with MOPAR(R) AS68RC ATF. 2. Install the output speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the wiring connector onto the output speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC ATF as necessary. Input Speed Sensor INPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 10289 INPUT SPEED SENSOR 1. Lubricate the output speed sensor O-ring with MOPAR(R) AS68RC ATF. 2. Install the input speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the electrical wiring connector onto the input speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC as necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Component ID: 431 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 TCC TEMPERATURE SIGNAL T819 20YL/VT 2 TEMPERATURE SENSOR GROUND T820 20YL/WT Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 10293 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 10294 Transmission Temperature Sensor/Switch: Diagrams Component ID: 431 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 TCC TEMPERATURE SIGNAL T819 20YL/VT 2 TEMPERATURE SENSOR GROUND T820 20YL/WT Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 10295 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection SWITCH-CLUTCH PEDAL POSITION 1. Disconnect switch 2-wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed - Continuity - Pedal Released - No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Description and Operation > Description Power Take-Off Switch: Description and Operation Description DESCRIPTION This Engine Control Module (ECM) input is used only on models equipped with aftermarket Power Take Off (PTO) units. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Description and Operation > Description > Page 10305 Power Take-Off Switch: Description and Operation Operation OPERATION This input is used only to tell the ECM that the aftermarket PTO (Power Take Off) unit has been engaged. The ECM will disable (temporarily shut down) certain OBD II diagnostic trouble codes when the PTO unit is engaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Component ID: 491 Component : SWITCH-TRANSFER CASE SELECTOR Connector: Name : SWITCH-TRANSFER CASE SELECTOR Color : BLACK # of pins : 10 Qualifier : (ETC) Pin Description Circuit 1 TRANSFER CASE POSITION SENSOR INPUT K77 20BR/WT 2-3 MODE SELECT K977 20BR/WT 4 PANEL LAMPS CONTROL E11 20OR/DB 5 GROUND Z905 20BK 6 NEUTRAL INDICATOR G95 20VT/BR 7 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 8-9-10 - Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 10310 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 10311 Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 10312 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 10313 Four Wheel Drive Selector Switch: Diagrams Component ID: 491 Component : SWITCH-TRANSFER CASE SELECTOR Connector: Name : SWITCH-TRANSFER CASE SELECTOR Color : BLACK # of pins : 10 Qualifier : (ETC) Pin Description Circuit 1 TRANSFER CASE POSITION SENSOR INPUT K77 20BR/WT 2-3 MODE SELECT K977 20BR/WT 4 PANEL LAMPS CONTROL E11 20OR/DB 5 GROUND Z905 20BK 6 NEUTRAL INDICATOR G95 20VT/BR 7 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 8-9-10 - Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 10314 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 10315 Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 10316 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case Four Wheel Drive Selector Switch: Description and Operation NV243 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 10319 For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere, is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 10320 Four Wheel Drive Selector Switch: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: - the AWD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 10321 The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 10322 Four Wheel Drive Selector Switch: Description and Operation NV246 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: - the AWD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 10323 For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 10324 Four Wheel Drive Selector Switch: Description and Operation NV273 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 10325 For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor Gear Sensor/Switch: Locations Assembly-Shift Motor/Mode Sensor Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10330 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10331 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10332 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10333 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10334 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10335 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10336 Gear Sensor/Switch: Locations Sensor-Transfer Case Position Component ID: 429 Component : SENSOR-TRANSFER CASE POSITION Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC) Pin Description Circuit 1 MODE SENSOR A D201 20WT/DG Pin Description Circuit 1 MODE SENSOR A D201 18WT/DG 2 GROUND Z955 20BK 2 GROUND Z955 18BK 2 GROUND Z901 20BK Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10337 Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10338 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor Gear Sensor/Switch: Diagrams Assembly-Shift Motor/Mode Sensor Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10341 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10342 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10343 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10344 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10345 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10346 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10347 Gear Sensor/Switch: Diagrams Sensor-Transfer Case Position Component ID: 429 Component : SENSOR-TRANSFER CASE POSITION Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC) Pin Description Circuit 1 MODE SENSOR A D201 20WT/DG Pin Description Circuit 1 MODE SENSOR A D201 18WT/DG 2 GROUND Z955 20BK 2 GROUND Z955 18BK 2 GROUND Z901 20BK Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10348 Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10349 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case Gear Sensor/Switch: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10352 Mode Sensor Channel States Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10353 Gear Sensor/Switch: Description and Operation NV246 Transfer Case Description DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The FCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Front Control Module (FCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to for the sensor codes returned to the FCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angle Vs. Transfer Case Position Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10354 Mode Sensor Channel States Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10355 Gear Sensor/Switch: Description and Operation NV271 Transfer Case Description DESCRIPTION The transfer case position sensor is an electronic device whose output can be interpreted to indicate the transfer case's current operating mode. The sensor consists of a five position, resistive multiplexed circuit which returns a specific resistance value to the Powertrain Control Module (PCM) for each transfer case operating mode. The sensor is located on the top of the transfer case, just left of the transfer case centerline and rides against the sector plate roostercomb. The PCM supplies 5VDC (+/- 0.5V) to the sensor and monitors the return voltage to determine the sector plate, and therefore the transfer case, position. Operation OPERATION Operating Mode Versus Resistance Position Sensor Linear Movement Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10356 During normal vehicle operation, the Powertrain Control Module (PCM) monitors the transfer case position sensor return voltage to determine the operating mode of the transfer case. Refer to the Operating Mode Versus Resistance table for the correct resistance for each position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10357 Gear Sensor/Switch: Description and Operation NV243 Transfer Case Description DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10358 Mode Sensor Channel States Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10359 Gear Sensor/Switch: Description and Operation NV273 Transfer Case Description DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10360 Mode Sensor Channel States Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Removal Gear Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Disengage the transfer case position sensor connector from the position sensor. 3. Remove the position sensor from the transfer case. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Removal > Page 10363 Gear Sensor/Switch: Service and Repair Installation INSTALLATION 1. Inspect the O-ring seal on the transfer case position sensor. Replace the O-ring if necessary. 2. Install the transfer case position sensor into the transfer case. Torque the sensor to 27 Nm (20 ft.lbs.). 3. Engage the transfer case position sensor connector to the position sensor. 4. Lower vehicle. 5. Verify proper sensor operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front Speed Sensor: Locations Sensor-Prop Shaft Speed-Front Component ID: 420 Component : SENSOR-PROP SHAFT SPEED-FRONT Connector: Name : SENSOR-PROP SHAFT SPEED-FRONT Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR 2 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 10368 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 10369 Speed Sensor: Locations Sensor-Prop Shaft Speed-Rear Component ID: 421 Component : SENSOR-PROP SHAFT SPEED-REAR Connector: Name : SENSOR-PROP SHAFT SPEED-REAR Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 2 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 10370 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front Speed Sensor: Diagrams Sensor-Prop Shaft Speed-Front Component ID: 420 Component : SENSOR-PROP SHAFT SPEED-FRONT Connector: Name : SENSOR-PROP SHAFT SPEED-FRONT Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR 2 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 10373 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 10374 Speed Sensor: Diagrams Sensor-Prop Shaft Speed-Rear Component ID: 421 Component : SENSOR-PROP SHAFT SPEED-REAR Connector: Name : SENSOR-PROP SHAFT SPEED-REAR Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 2 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 10375 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Sensor-Output Shaft Speed-Front Speed Sensor: Service and Repair Sensor-Output Shaft Speed-Front Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connector from the front output shaft speed sensor (1). 3. Remove the front output shaft speed sensor from the transfer case. Installation INSTALLATION 1. Install the front output shaft speed sensor (1) into the transfer case. Tighten the speed sensor to 17 Nm (12.5 ft.lbs.). 2. Engage the wiring connector to the front output shaft speed sensor. 3. Lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Sensor-Output Shaft Speed-Front > Page 10378 Speed Sensor: Service and Repair Sensor-Output Shaft Speed-Rear Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connector from the rear output shaft speed sensor (1). 3. Remove the rear output shaft speed sensor from the transfer case. Installation INSTALLATION 1. Install the rear output shaft speed sensor (1) into the transfer case. Tighten the speed sensor to 17 Nm (12.5 ft.lbs.). 2. Engage the wiring connector to the rear output shaft speed sensor. 3. Lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations Transfer Case Actuator: Locations Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10384 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10385 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10386 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10387 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10388 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10389 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10390 Transfer Case Actuator: Diagrams Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10391 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10392 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10393 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10394 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10395 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10396 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case Transfer Case Actuator: Description and Operation NV243 Transfer Case Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 10399 torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 10400 Transfer Case Actuator: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 10401 Transfer Case Actuator: Description and Operation NV246 Transfer Case Description DESCRIPTION The shift motor consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Front Control Module (FCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 10402 Transfer Case Actuator: Description and Operation NV273 Transfer Case Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case Transfer Case Actuator: Service and Repair NV243 Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. Installation INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 10405 Transfer Case Actuator: Service and Repair NV244 GENII Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. Installation INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 10406 Transfer Case Actuator: Service and Repair NV246 Transfer Case Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Remove the front propeller shaft. 3. Disengage the wiring connectors from the shift motor and mode sensor. 4. Remove the bolts (1) holding the shift motor and mode sensor assembly (2) onto the transfer case. 5. Separate the shift motor and mode sensor assembly (1) from the transfer case. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 10407 6. Remove the shift motor isolator (1) from the transfer case (2). Installation INSTALLATION 1. Install the shift motor isolator (1) onto the transfer case (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 10408 NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Install the shift motor and mode sensor assembly (1) onto the transfer case. CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 3. Install the bolts (1) to hold the shift motor and mode sensor assembly (2) onto the transfer case. Tighten the bolts to 23.5 Nm (17 ft.lbs.). 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Install the front propeller shaft. 6. Refill the transfer case as necessary with the correct fluid for the application. 7. Lower vehicle and verify transfer case operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 10409 Transfer Case Actuator: Service and Repair NV273 Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. Installation INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations Control Module: Locations Component ID: 204 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 LOCKER SENSOR SUPPLY T521 20YL/BK A2 LOCKER SWITCH SUPPLY T537 20YL/LG A3 LOCKER SENSOR SUPPLY T523 20YL/BK A4 - A5 - A6 CAN C BUS (+) D65 20WT/LG A7 CAN C BUS (-) D64 20WT/LB A8 REAR LOCKER SENSOR SENSE T527 20YL/TN A9 FRONT LOCKER SENSOR SENSE T522 20YL/LB A10 LOCKER SWITCH SENSE T535 20YL/BR A11 - A12 - A13 - A14 - B FUSED B(+) A121 14RD/YL B1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG B2 SWITCH SUPPLY T536 20YL/WT B3 - B4 - B5 STABILIZER BAR SWITCH SENSE T531 20YL/TN B6 LOCKER OPEN ILLUMINATION SENSE T532 20YL/GY B7 LOCKER REAR ILLUMINATION SENSE T533 20YL/LB B8 LOCKER FR/RR ILLUMINATION SENSE T534 20YL B9 STABILIZER BAR DISENGAGE ILLUMINATION SENSE T530 20YL/DG B10 STABILIZER BAR ENGAGE ILLUMINATION SENSE T529 20YL/LG B11 - B12 - B13 - B14 - C FRONT LOCKER SOURCE T520 16YL/OR C1 - C2 - C3 - C4 - C5 - - Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 10413 C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - D REAR LOCKER SOURCE T526 16YL/WT E GROUND Z935 16BK F GROUND Z935 16BK G FRONT LOCKER RETURN T524 16YL/LG H REAR LOCKER RETURN T528 16YL/GY Component Location - 29 Component Location - 28 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 10414 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 10415 Control Module: Diagrams Component ID: 204 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 LOCKER SENSOR SUPPLY T521 20YL/BK A2 LOCKER SWITCH SUPPLY T537 20YL/LG A3 LOCKER SENSOR SUPPLY T523 20YL/BK A4 - A5 - A6 CAN C BUS (+) D65 20WT/LG A7 CAN C BUS (-) D64 20WT/LB A8 REAR LOCKER SENSOR SENSE T527 20YL/TN A9 FRONT LOCKER SENSOR SENSE T522 20YL/LB A10 LOCKER SWITCH SENSE T535 20YL/BR A11 - A12 - A13 - A14 - B FUSED B(+) A121 14RD/YL B1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG B2 SWITCH SUPPLY T536 20YL/WT B3 - B4 - B5 STABILIZER BAR SWITCH SENSE T531 20YL/TN B6 LOCKER OPEN ILLUMINATION SENSE T532 20YL/GY B7 LOCKER REAR ILLUMINATION SENSE T533 20YL/LB B8 LOCKER FR/RR ILLUMINATION SENSE T534 20YL B9 STABILIZER BAR DISENGAGE ILLUMINATION SENSE T530 20YL/DG B10 STABILIZER BAR ENGAGE ILLUMINATION SENSE T529 20YL/LG B11 - B12 - B13 - B14 - C FRONT LOCKER SOURCE T520 16YL/OR C1 - C2 - C3 - C4 - C5 - - Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 10416 C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - D REAR LOCKER SOURCE T526 16YL/WT E GROUND Z935 16BK F GROUND Z935 16BK G FRONT LOCKER RETURN T524 16YL/LG H REAR LOCKER RETURN T528 16YL/GY Component Location - 29 Component Location - 28 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 10417 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description Control Module: Description and Operation Description DESCRIPTION The Transfer Case Control Module (TCCM) functionality now resides in the Totally Integrated Power Module (TIPM), refer to the TIPM information for location. The TIPM controls the 4X4 transfer case shift functions via the actuation of a shift motor and utilizing the feedback of a mode sensor assembly. Communication is via the CAN bus. Inputs include user selectable 4X4 modes that include 2WD, AWD, 4HI, 4LO, and Neutral (selections vary with the specific transfer case). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 10420 Control Module: Description and Operation Operation OPERATION The Transfer Case Control Module (TCCM) functionality in the Totally Integrated Power Module (TIPM) utilizes the input from the transfer case mounted mode sensor, the instrument panel mounted selector switch, and the following information from the vehicle's CAN bus to determine if a shift is allowed. - Engine RPM and Vehicle Speed - Diagnostic Requests - Manual Transmission and Brake Applied - PRNDL - Ignition Status - ABS Messages Once the TIP determines that a requested shift is allowed, it actuates the bi-directional shift motor as necessary to achieve the desired transfer case operating mode. The TIPM also monitors the mode sensor while controlling the shift motor to determine the status of the shift attempt. Several items can cause the requested shift not to be completed. If the TIPM has recognized a fault (DTC) of some variety, it will begin operation in one of four Functionality Levels. These levels are: - Level Zero - Normal Operation. - Level One - Only Mode Shifts Are Allowed. - Level Two - Only Mode Shifts and Shifts Into LOW Are Allowed (No Neutral Shifts Are Allowed). - Level Three - No Shifts Are Allowed The TIPM can also be operating in one of three possible power modes. These power modes are: - Full Power Mode is the normal operational mode of the module. This mode is achieved by normal CAN bus traffic being present and the ignition being in the RUN position. Reduced Power Mode will be entered when the ignition has been powered off. In this state, the module will shut down power supplied to external devices, and to electronic interface inputs and outputs. From this state the module can enter either Sleep Mode or Full Power Mode. To enter this mode, the module must receive an ignition message denoting that the ignition is off, or not receive any messages for 5 ± 0.5 seconds. To exit this mode, the module must receive one ignition message that denotes that the ignition is in the RUN position. - Sleep Mode will be entered, from the Reduced Power Mode, when no CAN traffic has been sensed for 20 ± 1 seconds. If during Sleep Mode the module detects CAN bus traffic, it will revert to the Reduced Power mode while monitoring for ignition messages. It will remain in this state as long as there is traffic other than run or start messages, and will return to Sleep mode if the bus goes without traffic for 20 ± 1 seconds. SHIFT REQUIREMENTS If the TIPM is in full power mode and at functionality level zero, it uses the following criteria to determine if a shift is allowed. If any of the driver controllable conditions are not met once the shift request is recognized, the TIPM will solidly illuminate the source position's LED and flash the desired position's LED for all shifts except NEUTRAL. The NEUTRAL shift LED strategy will be discussed later. Mode shifts will be allowed regardless of transmission gear or vehicle speed, whenever the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - A change in the Selector switch state indicates that a mode shift has been requested. - A valid mode sensor signal is being sensed by the TIPM. - Proper transmit/receive messages are occurring on the CAN bus. - Ignition key switch is in the RUN position. Range shifts will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - A change in the Selector Switch state indicating a range shift has been requested. - Transmission in NEUTRAL signal must be recognized for at least 1.5 seconds ± 100 msec. (Automatic transmissions only) - Proper transmit/receive messages are occurring on the CAN bus. - Clutch signal is recognized for 500 msec ± 50 msec (Manual transmissions only). - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position. - A valid mode sensor signal is being sensed by the TIPM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 10421 A shift into transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 4.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus. (Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the CAN bus. - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position, engine off. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TIPM. A shift out of transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 1.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus.(Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the CAN bus. - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TIPM. SHIFT SEQUENCES Once all the driver controllable conditions for the requested shift have been met, the TIPM begins a shift timer with a maximum duration of 1 second per 'D' channel transition. If the shift timer expires before the TIPM recognizes to correct mode sensor code, the shift is considered to have been blocked. The blocked shift will increment the blocked shift counter by one. The TIPM strategy for handling blocked shifts will be described later. The process the TIPM performs for the various shifts will be described first. RANGE AND MODE SHIFTS The process for performing all the range and mode shifts are the same. The following steps describe the process. - Allow time for Selector Switch debounce; 250 msec ± 50 msec. - Extinguish the source gear's LED while flashing desired transfer case position's LED. - Engage the shift motor for a maximum of 1 second ± 100 msec per 'D' channel transition in the destination gear's direction while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Solidly illuminate the selected gear's LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds ± 100 msec. per 'D' channel. The TIPM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. The exception to the preceding sequence is when a shift from 4L to 2WD/AWD is requested. If 2WD/AWD is requested from the 4L position, the transfer case is first driven to the 4H position. If the 4H position is reached, the transfer case is then driven back to the 2WD/AWD position and the shift is considered complete. If the transfer case does not reach any the 4H position, but is in the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is also considered complete. SHIFT OUT OF NEUTRAL The following steps describe the process for a shift out of NEUTRAL. - Extinguish the Neutral LED. - Engage the shift motor for a maximum of 1 second ± 100 msec toward the transfer case 4H mode position while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Extinguish the Neutral LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds 100 msec. The Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 10422 TIPM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. - When the Neutral button is released, if the 4H position is the desired position, the shift is complete. Illuminate the 4H LED. - Otherwise when the Neutral button is released, if all of the shift requirements are being met then engage the shift motor towards the desired position for 1 second ± 100 msec per 'D' channel. (if requirements for shifting are not met, illuminate the 4H LED and flash the destination LED as an indication to the driver that all of the driver controllable shift conditions are not being met). If this requires another range or mode shift, begin the range/mode shift process. - If the desired mode sensor code is not received after the shift timer expires (i.e. a blocked or other condition exists), refer to Blocked Shift Strategy. BLOCKED SHIFT STRATEGY When a shift is commanded, the shift motor will be driven towards its destination position, except in the case of shifting out of Neutral if 4L was selected (the transfer case will shift to the 4H position first, before proceeding to 4L). If the shift is blocked on the way to the destination, the TIPM may attempt to drive the motor back to the original position. This process will be allowed to occur 5 times. If the transfer case has reached a non-NEUTRAL 'D' channel during the shift re-attempts, the LED for the achieved gear position is illuminated and the shift attempts are stopped. To re-attempt the desired shift, the selector switch will need to be rotated to the current position until the switch debounce timer expires then a shift will need to be requested again. At the end of the 5th blocked attempt, the shift motor is driven towards the last known 'D' channel position. If this motor drive allows the transfer case to reach the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is considered complete and the shift attempts are ended. If the mode sensor is in the NEUTRAL region at the expiration of the shift timer, the TIPM will continue to make the shift attempts according to the blocked shift strategy independent of whether or not the driver controlled conditions are met. For shifts from NEUTRAL, if all 5 attempts fail to reach the desired position (which by default is 4H), the motor will be driven to stall in the direction of 4H or 4L, depending on the achieved position. If the transfer case has reached the 2WD/AWD or 4L between gear position nearest the NEUTRAL positions and the shift conditions are no longer being met, the transfer case will be driven toward the corresponding 'D' channel. Otherwise, the transfer case will be driven in the direction opposite the last attempt with the desired target being 4H or 4L. If the transfer case reaches the 2WD/AWD 'D' channel when being driven in the 4H direction, then one final 1.0 second drive toward 4H is attempted. If the transfer case then reaches any of the 4H positions, the shift is considered complete and the 4H LED is illuminated. If the transfer case is still the 2WD/AWD position, the shift is considered complete and the 2WD/AWD LED is illuminated. NOTE: If after the 5th blocked shift and reversal attempt, if the transfer case position is in the NEUTRAL region, shift attempts will continue until a non-NEUTRAL 'D' channel is reached. SHIFT REVERSAL TARGETS If the shift timer expires (1 second per 'D' channel) and the transfer case has not reached the desired position, all shifts will attempt to return to their original position with the exceptions of: - If the intended shift is going to the High rail from Low and can't make it, but it can make the 2WD/AWD position, the motor stops at that position. The TIPM will not attempt to cross back over NEUTRAL if it does not have to. This means that there was a block on the first attempt to go to 4H and the transfer case has made it through NEUTRAL to a known good position, then the motor will go back only to the 2WD/4WD position and execute the remainder of the attempts from there. - For shifts out of NEUTRAL, any time a shift is commanded out of NEUTRAL, the system needs to get out. The TIPM should never go to NEUTRAL unless the driver is commanding it and all required conditions are being met ENCODER DRIFT CORRECTION Whenever a shift is completed, the TIPM stores the position in memory as the transfer case's intended position. The TIPM continuously monitors the mode sensor and if the mode sensor drifts toward into a NEUTRAL region sensor position for 2.0 seconds, the TIPM will perform a motor drive to correct the drift. The transfer case will be driven toward the intended position for 1.0 seconds ± 100 msec. The TIPM will wait for 2.0 seconds ± 50 msec. and repeat the attempt to shift to the desired position. This will continue until the intended position is reached. SHIFT MOTOR BRAKING Two modes of shift motor braking are employed to improve shift performance, static and dynamic. Static shift motor braking is utilized under the following conditions: - Whenever the transfer case is in the 2WD/AWD or 4L 'D' channel position. - Whenever an invalid mode sensor code is present. Static motor braking is achieved by applying +12V on both shift motor wires. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 10423 NOTE: Static Shift Motor Braking is independent of ignition key position. SHIFT ATTEMPT LIMIT To protect the transfer case system, the TIPM will impose a limit on the number of shifts that can occur over a calibrated time period. The system will monitor the number of 'D' channel segment transitions that occur in any 30 second time period. If the number of segment transitions is 30 or greater, the system will go into a default mode. The default mode of operation for shifting is that the number of allowed 'D' channel transitions permitted to occur will be 3 over each 15 second ± 100 msec calibrated window of time. After 5 minutes ± 100 msec, the motor can be assumed to have cooled down and the system will revert to normal operation. The following rules also apply to the shift limit: - The attempt limit will not prevent shifts coming out of NEUTRAL, they will be allowed regardless of the counter/timer. - Any shift that is in progress when the counter reaches a maximum count in time will be allowed to complete before the default mode is entered. D-channel transitions during this period will not be counted towards the default mode limit. - A block, regardless of the direction, whether towards destination or back towards reversal target (shift timer expiring), will count as a value of 2 transitions towards the 30 segment transitions to go into default mode as defined above. Current attempt limit values are 30 transitions in 30 seconds and default mode values are 3 transitions every 15 seconds for 5 minutes. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 10429 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 10434 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications TRANSFER CASE FLUID CAPACITY NV241 GENII ....................................................................................................................................... ........................................................... 1.6 L (3.4 Pt) NV243 ................................................................ .............................................................................................................................................. 1.6 L (3.4 Pt) NV244 GENII .......................................................................................................................... ........................................................................ 1.6 L (3.4 Pt) NV 246 .................................................. ........................................................................................................................................................... 1.9 L (4.0 Pt) NV271 ............................................................................................................................ ................................................................................ 1.89 L (4.0 Pt) NV273 ......................................... .............................................................................................................................................................. ..... 1.89 L (4.0 Pt) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 10437 Fluid - Transfer Case: Fluid Type Specifications TRANSFER CASE LUBRICANT All except NV246 ......................................................................................................................................... Mopar ATF +4 Automatic Transmission Fluid NV246 ....................................................................................................................................................... Mopar NVG246 Automatic Transmission Fluid Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case Fluid - Transfer Case: Service and Repair NV241 GENII Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 10440 Fluid - Transfer Case: Service and Repair NV271 Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (1) and drain (2) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 10441 Fluid - Transfer Case: Service and Repair NV243 Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 10442 Fluid - Transfer Case: Service and Repair NV244 GENII Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL NOTE: The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain (3) and fill (2) plugs and drain lubricant completely. 4. Install drain plug (3). Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug (2) to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 10443 Fluid - Transfer Case: Service and Repair NV241 GENII Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. NV271 Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (1) and drain (2) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 10444 NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. NV243 Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. NV244 GENII Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 10445 NOTE: The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain (3) and fill (2) plugs and drain lubricant completely. 4. Install drain plug (3). Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug (2) to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. NV246 Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (2) and drain (1) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 27 Nm (20 ft. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 10446 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with the correct fluid for the application. 7. Install and tighten fill plug to 27 Nm (20 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. NV273 Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (1) and drain (2) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description Four Wheel Drive Indicator Lamp: Description and Operation Description 4WD Auto Indicator 4WD AUTO INDICATOR A 4WD auto indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD auto indicator is located on the right side of the instrument cluster, to the right of the oil pressure gauge. The 4WD auto indicator consists of a stencil-like cutout of the text 4WD AUTO in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD auto indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD auto indicator is serviced as a unit with the instrument cluster. 4WD Indicator 4WD INDICATOR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 10451 A 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional four-wheel drive system, this indicator is electronically disabled. The 4WD indicator is located on the right side of the instrument cluster, to the right of the oil pressure gauge. The 4WD indicator consists of a stencil-like cutout of the text 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD indicator is serviced as a unit with the instrument cluster. 4WD Low Indicator 4WD LOW INDICATOR A 4WD low indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD low indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The 4WD low indicator consists of a stencil-like cutout of the text 4WD LOW in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD low indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD low indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 10452 Four Wheel Drive Indicator Lamp: Description and Operation Operation 4WD Auto Indicator 4WD AUTO INDICATOR The 4WD auto indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD auto mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD auto indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD auto indicator for the following reasons: - 4WD Auto Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD auto indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD auto indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD auto mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD auto indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD auto indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. 4WD Indicator 4WD INDICATOR The 4WD indicator gives an indication to the vehicle operator when the transfer case has been shifted into a 4WD mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD indicator for the following reasons: - 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly or the manual transfer case through the transfer case switch to determine when the 4WD mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the transfer case switch, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. 4WD Low Indicator 4WD LOW INDICATOR The 4WD low indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD low mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD low indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 10453 indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD low indicator for the following reasons: - 4WD Low Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD low indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD low indicator will be turned ON, then OFF again during the LED portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD low mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD low indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD low indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Component ID: 491 Component : SWITCH-TRANSFER CASE SELECTOR Connector: Name : SWITCH-TRANSFER CASE SELECTOR Color : BLACK # of pins : 10 Qualifier : (ETC) Pin Description Circuit 1 TRANSFER CASE POSITION SENSOR INPUT K77 20BR/WT 2-3 MODE SELECT K977 20BR/WT 4 PANEL LAMPS CONTROL E11 20OR/DB 5 GROUND Z905 20BK 6 NEUTRAL INDICATOR G95 20VT/BR 7 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 8-9-10 - Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 10457 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 10458 Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 10459 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 10460 Four Wheel Drive Selector Switch: Diagrams Component ID: 491 Component : SWITCH-TRANSFER CASE SELECTOR Connector: Name : SWITCH-TRANSFER CASE SELECTOR Color : BLACK # of pins : 10 Qualifier : (ETC) Pin Description Circuit 1 TRANSFER CASE POSITION SENSOR INPUT K77 20BR/WT 2-3 MODE SELECT K977 20BR/WT 4 PANEL LAMPS CONTROL E11 20OR/DB 5 GROUND Z905 20BK 6 NEUTRAL INDICATOR G95 20VT/BR 7 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 8-9-10 - Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 10461 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 10462 Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 10463 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case Four Wheel Drive Selector Switch: Description and Operation NV243 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 10466 For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere, is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 10467 Four Wheel Drive Selector Switch: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: - the AWD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 10468 The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 10469 Four Wheel Drive Selector Switch: Description and Operation NV246 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: - the AWD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 10470 For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 10471 Four Wheel Drive Selector Switch: Description and Operation NV273 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 10472 For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor Gear Sensor/Switch: Locations Assembly-Shift Motor/Mode Sensor Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10477 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10478 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10479 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10480 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10481 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10482 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10483 Gear Sensor/Switch: Locations Sensor-Transfer Case Position Component ID: 429 Component : SENSOR-TRANSFER CASE POSITION Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC) Pin Description Circuit 1 MODE SENSOR A D201 20WT/DG Pin Description Circuit 1 MODE SENSOR A D201 18WT/DG 2 GROUND Z955 20BK 2 GROUND Z955 18BK 2 GROUND Z901 20BK Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10484 Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10485 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor Gear Sensor/Switch: Diagrams Assembly-Shift Motor/Mode Sensor Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10488 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10489 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10490 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10491 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10492 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10493 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10494 Gear Sensor/Switch: Diagrams Sensor-Transfer Case Position Component ID: 429 Component : SENSOR-TRANSFER CASE POSITION Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC) Pin Description Circuit 1 MODE SENSOR A D201 20WT/DG Pin Description Circuit 1 MODE SENSOR A D201 18WT/DG 2 GROUND Z955 20BK 2 GROUND Z955 18BK 2 GROUND Z901 20BK Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10495 Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10496 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case Gear Sensor/Switch: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10499 Mode Sensor Channel States Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10500 Gear Sensor/Switch: Description and Operation NV246 Transfer Case Description DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The FCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Front Control Module (FCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to for the sensor codes returned to the FCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angle Vs. Transfer Case Position Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10501 Mode Sensor Channel States Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10502 Gear Sensor/Switch: Description and Operation NV271 Transfer Case Description DESCRIPTION The transfer case position sensor is an electronic device whose output can be interpreted to indicate the transfer case's current operating mode. The sensor consists of a five position, resistive multiplexed circuit which returns a specific resistance value to the Powertrain Control Module (PCM) for each transfer case operating mode. The sensor is located on the top of the transfer case, just left of the transfer case centerline and rides against the sector plate roostercomb. The PCM supplies 5VDC (+/- 0.5V) to the sensor and monitors the return voltage to determine the sector plate, and therefore the transfer case, position. Operation OPERATION Operating Mode Versus Resistance Position Sensor Linear Movement Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10503 During normal vehicle operation, the Powertrain Control Module (PCM) monitors the transfer case position sensor return voltage to determine the operating mode of the transfer case. Refer to the Operating Mode Versus Resistance table for the correct resistance for each position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10504 Gear Sensor/Switch: Description and Operation NV243 Transfer Case Description DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10505 Mode Sensor Channel States Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10506 Gear Sensor/Switch: Description and Operation NV273 Transfer Case Description DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10507 Mode Sensor Channel States Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Removal Gear Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Disengage the transfer case position sensor connector from the position sensor. 3. Remove the position sensor from the transfer case. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Removal > Page 10510 Gear Sensor/Switch: Service and Repair Installation INSTALLATION 1. Inspect the O-ring seal on the transfer case position sensor. Replace the O-ring if necessary. 2. Install the transfer case position sensor into the transfer case. Torque the sensor to 27 Nm (20 ft.lbs.). 3. Engage the transfer case position sensor connector to the position sensor. 4. Lower vehicle. 5. Verify proper sensor operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description Four Wheel Drive Indicator Lamp: Description and Operation Description 4WD Auto Indicator 4WD AUTO INDICATOR A 4WD auto indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD auto indicator is located on the right side of the instrument cluster, to the right of the oil pressure gauge. The 4WD auto indicator consists of a stencil-like cutout of the text 4WD AUTO in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD auto indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD auto indicator is serviced as a unit with the instrument cluster. 4WD Indicator 4WD INDICATOR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 10516 A 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional four-wheel drive system, this indicator is electronically disabled. The 4WD indicator is located on the right side of the instrument cluster, to the right of the oil pressure gauge. The 4WD indicator consists of a stencil-like cutout of the text 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD indicator is serviced as a unit with the instrument cluster. 4WD Low Indicator 4WD LOW INDICATOR A 4WD low indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD low indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The 4WD low indicator consists of a stencil-like cutout of the text 4WD LOW in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD low indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD low indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 10517 Four Wheel Drive Indicator Lamp: Description and Operation Operation 4WD Auto Indicator 4WD AUTO INDICATOR The 4WD auto indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD auto mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD auto indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD auto indicator for the following reasons: - 4WD Auto Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD auto indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD auto indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD auto mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD auto indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD auto indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. 4WD Indicator 4WD INDICATOR The 4WD indicator gives an indication to the vehicle operator when the transfer case has been shifted into a 4WD mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD indicator for the following reasons: - 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly or the manual transfer case through the transfer case switch to determine when the 4WD mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the transfer case switch, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. 4WD Low Indicator 4WD LOW INDICATOR The 4WD low indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD low mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD low indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 10518 indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD low indicator for the following reasons: - 4WD Low Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD low indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD low indicator will be turned ON, then OFF again during the LED portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD low mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD low indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD low indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Description Malfunction Indicator Lamp - Transfer Case: Description and Operation Description DESCRIPTION A service 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The service 4WD indicator consists of a stencil-like cutout of the text SVC 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The service 4WD indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Description > Page 10523 Malfunction Indicator Lamp - Transfer Case: Description and Operation Operation OPERATION The service 4WD indicator gives an indication to the vehicle operator when the Totally Integrated Power Module (TIPM) has recorded a Diagnostic Trouble Code (DTC) for an electronic transfer case circuit or component malfunction. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the TIPM over the Controller Area Network (CAN) data bus. The service 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the service 4WD indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the service 4WD indicator is illuminated for about two seconds as a bulb test. - Service 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic service 4WD indicator lamp-ON message from the TIPM, the service 4WD indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the TIPM for 10 seconds the service 4WD indicator is illuminated by the cluster to indicate a loss of TIPM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the TIPM. - Actuator Test - Each time the cluster is put through the actuator test, the service 4WD indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case control circuits and transfer case shift motor/mode sensor assembly to determine the condition of the system. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the service 4WD indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the TIPM, the EMIC, the CAN data bus or the electronic communication related to service 4WD indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Description Malfunction Indicator Lamp - Transfer Case: Description and Operation Description DESCRIPTION A service 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The service 4WD indicator consists of a stencil-like cutout of the text SVC 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The service 4WD indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Description > Page 10528 Malfunction Indicator Lamp - Transfer Case: Description and Operation Operation OPERATION The service 4WD indicator gives an indication to the vehicle operator when the Totally Integrated Power Module (TIPM) has recorded a Diagnostic Trouble Code (DTC) for an electronic transfer case circuit or component malfunction. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the TIPM over the Controller Area Network (CAN) data bus. The service 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the service 4WD indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the service 4WD indicator is illuminated for about two seconds as a bulb test. - Service 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic service 4WD indicator lamp-ON message from the TIPM, the service 4WD indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the TIPM for 10 seconds the service 4WD indicator is illuminated by the cluster to indicate a loss of TIPM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the TIPM. - Actuator Test - Each time the cluster is put through the actuator test, the service 4WD indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case control circuits and transfer case shift motor/mode sensor assembly to determine the condition of the system. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the service 4WD indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the TIPM, the EMIC, the CAN data bus or the electronic communication related to service 4WD indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Control Module: Locations Component ID: 204 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 LOCKER SENSOR SUPPLY T521 20YL/BK A2 LOCKER SWITCH SUPPLY T537 20YL/LG A3 LOCKER SENSOR SUPPLY T523 20YL/BK A4 - A5 - A6 CAN C BUS (+) D65 20WT/LG A7 CAN C BUS (-) D64 20WT/LB A8 REAR LOCKER SENSOR SENSE T527 20YL/TN A9 FRONT LOCKER SENSOR SENSE T522 20YL/LB A10 LOCKER SWITCH SENSE T535 20YL/BR A11 - A12 - A13 - A14 - B FUSED B(+) A121 14RD/YL B1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG B2 SWITCH SUPPLY T536 20YL/WT B3 - B4 - B5 STABILIZER BAR SWITCH SENSE T531 20YL/TN B6 LOCKER OPEN ILLUMINATION SENSE T532 20YL/GY B7 LOCKER REAR ILLUMINATION SENSE T533 20YL/LB B8 LOCKER FR/RR ILLUMINATION SENSE T534 20YL B9 STABILIZER BAR DISENGAGE ILLUMINATION SENSE T530 20YL/DG B10 STABILIZER BAR ENGAGE ILLUMINATION SENSE T529 20YL/LG B11 - B12 - B13 - B14 - C FRONT LOCKER SOURCE T520 16YL/OR C1 - C2 - C3 - C4 - C5 - - Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 10533 C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - D REAR LOCKER SOURCE T526 16YL/WT E GROUND Z935 16BK F GROUND Z935 16BK G FRONT LOCKER RETURN T524 16YL/LG H REAR LOCKER RETURN T528 16YL/GY Component Location - 29 Component Location - 28 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 10534 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 10535 Control Module: Diagrams Component ID: 204 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 LOCKER SENSOR SUPPLY T521 20YL/BK A2 LOCKER SWITCH SUPPLY T537 20YL/LG A3 LOCKER SENSOR SUPPLY T523 20YL/BK A4 - A5 - A6 CAN C BUS (+) D65 20WT/LG A7 CAN C BUS (-) D64 20WT/LB A8 REAR LOCKER SENSOR SENSE T527 20YL/TN A9 FRONT LOCKER SENSOR SENSE T522 20YL/LB A10 LOCKER SWITCH SENSE T535 20YL/BR A11 - A12 - A13 - A14 - B FUSED B(+) A121 14RD/YL B1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG B2 SWITCH SUPPLY T536 20YL/WT B3 - B4 - B5 STABILIZER BAR SWITCH SENSE T531 20YL/TN B6 LOCKER OPEN ILLUMINATION SENSE T532 20YL/GY B7 LOCKER REAR ILLUMINATION SENSE T533 20YL/LB B8 LOCKER FR/RR ILLUMINATION SENSE T534 20YL B9 STABILIZER BAR DISENGAGE ILLUMINATION SENSE T530 20YL/DG B10 STABILIZER BAR ENGAGE ILLUMINATION SENSE T529 20YL/LG B11 - B12 - B13 - B14 - C FRONT LOCKER SOURCE T520 16YL/OR C1 - C2 - C3 - C4 - C5 - - Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 10536 C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - D REAR LOCKER SOURCE T526 16YL/WT E GROUND Z935 16BK F GROUND Z935 16BK G FRONT LOCKER RETURN T524 16YL/LG H REAR LOCKER RETURN T528 16YL/GY Component Location - 29 Component Location - 28 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 10537 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description Control Module: Description and Operation Description DESCRIPTION The Transfer Case Control Module (TCCM) functionality now resides in the Totally Integrated Power Module (TIPM), refer to the TIPM information for location. The TIPM controls the 4X4 transfer case shift functions via the actuation of a shift motor and utilizing the feedback of a mode sensor assembly. Communication is via the CAN bus. Inputs include user selectable 4X4 modes that include 2WD, AWD, 4HI, 4LO, and Neutral (selections vary with the specific transfer case). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 10540 Control Module: Description and Operation Operation OPERATION The Transfer Case Control Module (TCCM) functionality in the Totally Integrated Power Module (TIPM) utilizes the input from the transfer case mounted mode sensor, the instrument panel mounted selector switch, and the following information from the vehicle's CAN bus to determine if a shift is allowed. - Engine RPM and Vehicle Speed - Diagnostic Requests - Manual Transmission and Brake Applied - PRNDL - Ignition Status - ABS Messages Once the TIP determines that a requested shift is allowed, it actuates the bi-directional shift motor as necessary to achieve the desired transfer case operating mode. The TIPM also monitors the mode sensor while controlling the shift motor to determine the status of the shift attempt. Several items can cause the requested shift not to be completed. If the TIPM has recognized a fault (DTC) of some variety, it will begin operation in one of four Functionality Levels. These levels are: - Level Zero - Normal Operation. - Level One - Only Mode Shifts Are Allowed. - Level Two - Only Mode Shifts and Shifts Into LOW Are Allowed (No Neutral Shifts Are Allowed). - Level Three - No Shifts Are Allowed The TIPM can also be operating in one of three possible power modes. These power modes are: - Full Power Mode is the normal operational mode of the module. This mode is achieved by normal CAN bus traffic being present and the ignition being in the RUN position. Reduced Power Mode will be entered when the ignition has been powered off. In this state, the module will shut down power supplied to external devices, and to electronic interface inputs and outputs. From this state the module can enter either Sleep Mode or Full Power Mode. To enter this mode, the module must receive an ignition message denoting that the ignition is off, or not receive any messages for 5 ± 0.5 seconds. To exit this mode, the module must receive one ignition message that denotes that the ignition is in the RUN position. - Sleep Mode will be entered, from the Reduced Power Mode, when no CAN traffic has been sensed for 20 ± 1 seconds. If during Sleep Mode the module detects CAN bus traffic, it will revert to the Reduced Power mode while monitoring for ignition messages. It will remain in this state as long as there is traffic other than run or start messages, and will return to Sleep mode if the bus goes without traffic for 20 ± 1 seconds. SHIFT REQUIREMENTS If the TIPM is in full power mode and at functionality level zero, it uses the following criteria to determine if a shift is allowed. If any of the driver controllable conditions are not met once the shift request is recognized, the TIPM will solidly illuminate the source position's LED and flash the desired position's LED for all shifts except NEUTRAL. The NEUTRAL shift LED strategy will be discussed later. Mode shifts will be allowed regardless of transmission gear or vehicle speed, whenever the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - A change in the Selector switch state indicates that a mode shift has been requested. - A valid mode sensor signal is being sensed by the TIPM. - Proper transmit/receive messages are occurring on the CAN bus. - Ignition key switch is in the RUN position. Range shifts will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - A change in the Selector Switch state indicating a range shift has been requested. - Transmission in NEUTRAL signal must be recognized for at least 1.5 seconds ± 100 msec. (Automatic transmissions only) - Proper transmit/receive messages are occurring on the CAN bus. - Clutch signal is recognized for 500 msec ± 50 msec (Manual transmissions only). - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position. - A valid mode sensor signal is being sensed by the TIPM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 10541 A shift into transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 4.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus. (Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the CAN bus. - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position, engine off. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TIPM. A shift out of transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 1.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus.(Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the CAN bus. - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TIPM. SHIFT SEQUENCES Once all the driver controllable conditions for the requested shift have been met, the TIPM begins a shift timer with a maximum duration of 1 second per 'D' channel transition. If the shift timer expires before the TIPM recognizes to correct mode sensor code, the shift is considered to have been blocked. The blocked shift will increment the blocked shift counter by one. The TIPM strategy for handling blocked shifts will be described later. The process the TIPM performs for the various shifts will be described first. RANGE AND MODE SHIFTS The process for performing all the range and mode shifts are the same. The following steps describe the process. - Allow time for Selector Switch debounce; 250 msec ± 50 msec. - Extinguish the source gear's LED while flashing desired transfer case position's LED. - Engage the shift motor for a maximum of 1 second ± 100 msec per 'D' channel transition in the destination gear's direction while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Solidly illuminate the selected gear's LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds ± 100 msec. per 'D' channel. The TIPM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. The exception to the preceding sequence is when a shift from 4L to 2WD/AWD is requested. If 2WD/AWD is requested from the 4L position, the transfer case is first driven to the 4H position. If the 4H position is reached, the transfer case is then driven back to the 2WD/AWD position and the shift is considered complete. If the transfer case does not reach any the 4H position, but is in the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is also considered complete. SHIFT OUT OF NEUTRAL The following steps describe the process for a shift out of NEUTRAL. - Extinguish the Neutral LED. - Engage the shift motor for a maximum of 1 second ± 100 msec toward the transfer case 4H mode position while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Extinguish the Neutral LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds 100 msec. The Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 10542 TIPM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. - When the Neutral button is released, if the 4H position is the desired position, the shift is complete. Illuminate the 4H LED. - Otherwise when the Neutral button is released, if all of the shift requirements are being met then engage the shift motor towards the desired position for 1 second ± 100 msec per 'D' channel. (if requirements for shifting are not met, illuminate the 4H LED and flash the destination LED as an indication to the driver that all of the driver controllable shift conditions are not being met). If this requires another range or mode shift, begin the range/mode shift process. - If the desired mode sensor code is not received after the shift timer expires (i.e. a blocked or other condition exists), refer to Blocked Shift Strategy. BLOCKED SHIFT STRATEGY When a shift is commanded, the shift motor will be driven towards its destination position, except in the case of shifting out of Neutral if 4L was selected (the transfer case will shift to the 4H position first, before proceeding to 4L). If the shift is blocked on the way to the destination, the TIPM may attempt to drive the motor back to the original position. This process will be allowed to occur 5 times. If the transfer case has reached a non-NEUTRAL 'D' channel during the shift re-attempts, the LED for the achieved gear position is illuminated and the shift attempts are stopped. To re-attempt the desired shift, the selector switch will need to be rotated to the current position until the switch debounce timer expires then a shift will need to be requested again. At the end of the 5th blocked attempt, the shift motor is driven towards the last known 'D' channel position. If this motor drive allows the transfer case to reach the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is considered complete and the shift attempts are ended. If the mode sensor is in the NEUTRAL region at the expiration of the shift timer, the TIPM will continue to make the shift attempts according to the blocked shift strategy independent of whether or not the driver controlled conditions are met. For shifts from NEUTRAL, if all 5 attempts fail to reach the desired position (which by default is 4H), the motor will be driven to stall in the direction of 4H or 4L, depending on the achieved position. If the transfer case has reached the 2WD/AWD or 4L between gear position nearest the NEUTRAL positions and the shift conditions are no longer being met, the transfer case will be driven toward the corresponding 'D' channel. Otherwise, the transfer case will be driven in the direction opposite the last attempt with the desired target being 4H or 4L. If the transfer case reaches the 2WD/AWD 'D' channel when being driven in the 4H direction, then one final 1.0 second drive toward 4H is attempted. If the transfer case then reaches any of the 4H positions, the shift is considered complete and the 4H LED is illuminated. If the transfer case is still the 2WD/AWD position, the shift is considered complete and the 2WD/AWD LED is illuminated. NOTE: If after the 5th blocked shift and reversal attempt, if the transfer case position is in the NEUTRAL region, shift attempts will continue until a non-NEUTRAL 'D' channel is reached. SHIFT REVERSAL TARGETS If the shift timer expires (1 second per 'D' channel) and the transfer case has not reached the desired position, all shifts will attempt to return to their original position with the exceptions of: - If the intended shift is going to the High rail from Low and can't make it, but it can make the 2WD/AWD position, the motor stops at that position. The TIPM will not attempt to cross back over NEUTRAL if it does not have to. This means that there was a block on the first attempt to go to 4H and the transfer case has made it through NEUTRAL to a known good position, then the motor will go back only to the 2WD/4WD position and execute the remainder of the attempts from there. - For shifts out of NEUTRAL, any time a shift is commanded out of NEUTRAL, the system needs to get out. The TIPM should never go to NEUTRAL unless the driver is commanding it and all required conditions are being met ENCODER DRIFT CORRECTION Whenever a shift is completed, the TIPM stores the position in memory as the transfer case's intended position. The TIPM continuously monitors the mode sensor and if the mode sensor drifts toward into a NEUTRAL region sensor position for 2.0 seconds, the TIPM will perform a motor drive to correct the drift. The transfer case will be driven toward the intended position for 1.0 seconds ± 100 msec. The TIPM will wait for 2.0 seconds ± 50 msec. and repeat the attempt to shift to the desired position. This will continue until the intended position is reached. SHIFT MOTOR BRAKING Two modes of shift motor braking are employed to improve shift performance, static and dynamic. Static shift motor braking is utilized under the following conditions: - Whenever the transfer case is in the 2WD/AWD or 4L 'D' channel position. - Whenever an invalid mode sensor code is present. Static motor braking is achieved by applying +12V on both shift motor wires. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 10543 NOTE: Static Shift Motor Braking is independent of ignition key position. SHIFT ATTEMPT LIMIT To protect the transfer case system, the TIPM will impose a limit on the number of shifts that can occur over a calibrated time period. The system will monitor the number of 'D' channel segment transitions that occur in any 30 second time period. If the number of segment transitions is 30 or greater, the system will go into a default mode. The default mode of operation for shifting is that the number of allowed 'D' channel transitions permitted to occur will be 3 over each 15 second ± 100 msec calibrated window of time. After 5 minutes ± 100 msec, the motor can be assumed to have cooled down and the system will revert to normal operation. The following rules also apply to the shift limit: - The attempt limit will not prevent shifts coming out of NEUTRAL, they will be allowed regardless of the counter/timer. - Any shift that is in progress when the counter reaches a maximum count in time will be allowed to complete before the default mode is entered. D-channel transitions during this period will not be counted towards the default mode limit. - A block, regardless of the direction, whether towards destination or back towards reversal target (shift timer expiring), will count as a value of 2 transitions towards the 30 segment transitions to go into default mode as defined above. Current attempt limit values are 30 transitions in 30 seconds and default mode values are 3 transitions every 15 seconds for 5 minutes. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GENII Transfer Case Seals and Gaskets: Service and Repair NV241 GENII Transfer Case Removal REMOVAL 1. Raise and support vehicle. 2. Remove rear propeller shaft. 3. Using a suitable pry tool or slide-hammer mounted screw, remove the extension housing seal. Installation INSTALLATION 1. Clean fluid residue from sealing surface and inspect for defects. 2. Using Seal Installer D-163 (2) and Universal Handle C-4171 (1), install seal in extension housing. 3. Install propeller shaft. 4. Verify proper transfer case fluid level. 5. Lower vehicle. Removal REMOVAL 1. Remove the front propeller shaft. 2. Remove the front propeller shaft seal boot (1) retaining clamp (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GENII Transfer Case > Page 10548 3. Remove the front propeller shaft seal boot (1). 4. Remove the front output shaft seal slinger (1) by bending (2) the slinger ears away from the transfer case. 5. Using a suitable pry tool (2), remove the slinger (1) from the output shaft using care not to damage the shaft. 6. Using a screw and a slide hammer, remove the front output shaft seal. Installation INSTALLATION 1. Install the new front output shaft seal with Seal Installer MB991168A. 2. Install the front output shaft seal slinger with Oil Slinger Installer 8840. Install the slinger onto the shaft until the tool contacts the rear of the output shaft. 3. Install a new seal boot clamp onto the seal boot. 4. Install the seal boot and clamp onto the slinger hub and tighten the clamp with Axle Clamp Installer C-4975A. 5. Install front propeller shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GENII Transfer Case > Page 10549 Seals and Gaskets: Service and Repair NV243 Transfer Case Removal REMOVAL 1. Raise and support vehicle. 2. Remove rear propeller shaft. 3. Using a suitable pry tool or slide-hammer mounted screw, remove the extension housing seal. Installation INSTALLATION 1. Clean fluid residue from sealing surface and inspect for defects. 2. Using Seal Installer D-163 (2) and Universal Handle C-4171 (1), install seal in extension housing. 3. Install propeller shaft. 4. Verify proper transfer case fluid level. 5. Lower vehicle. Removal REMOVAL 1. Remove the front propeller shaft. 2. Remove the front propeller shaft seal boot (1) retaining clamp (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GENII Transfer Case > Page 10550 3. Remove the front propeller shaft seal boot (1). 4. Remove the front output shaft seal slinger (1) by bending (2) the slinger ears away from the transfer case. 5. Using a suitable pry tool (2), remove the slinger (1) from the output shaft using care not to damage the shaft. 6. Using a screw and a slide hammer, remove the front output shaft seal. Installation INSTALLATION 1. Install the new front output shaft seal with Seal Installer MB991168A. 2. Install the front output shaft seal slinger with Oil Slinger Installer 8840. Install the slinger onto the shaft until the tool contacts the rear of the output shaft. 3. Install a new seal boot clamp onto the seal boot. 4. Install the seal boot and clamp onto the slinger hub and tighten the clamp with Axle Clamp Installer C-4975A. 5. Install front propeller shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GENII Transfer Case > Page 10551 Seals and Gaskets: Service and Repair NV244 GENII Transfer Case Removal REMOVAL 1. Raise and support vehicle. 2. Remove rear propeller shaft. 3. Using a suitable pry tool or slide-hammer mounted screw, remove the extension housing seal. Installation INSTALLATION 1. Clean fluid residue from sealing surface and inspect for defects. 2. Using Seal Installer D-163 (2) and Universal Handle C-4171 (1), install seal in extension housing. 3. Install propeller shaft. 4. Verify proper transfer case fluid level. 5. Lower vehicle. Removal REMOVAL 1. Remove the front propeller shaft. 2. Remove the front propeller shaft seal boot retaining clamp (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GENII Transfer Case > Page 10552 3. Remove the front propeller shaft seal boot (1) from the front output shaft seal slinger (2). 4. Remove the front output shaft seal slinger (1) by bending the slinger away (2) from the transfer case. 5. Using a suitable pry tool, remove the slinger from the output shaft using care not to damage the shaft. 6. Using a screw and a slide hammer, remove the front output shaft seal. Installation INSTALLATION 1. Install the new front output shaft seal with Seal Installer MB991168A. 2. Install the front output shaft seal slinger with Oil Slinger Installer 8840. Install the slinger onto the shaft until the tool contacts the rear of the output shaft. 3. Install a new seal boot clamp onto the seal boot. 4. Install the seal boot and clamp onto the slinger hub and tighten the clamp with Axle Clamp Installer C-4975A. 5. Install front propeller shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GENII Transfer Case > Page 10553 Seals and Gaskets: Service and Repair NV246 Transfer Case Removal REMOVAL 1. Raise and support vehicle. 2. Remove rear propeller shaft. 3. Using a suitable pry tool or slide-hammer mounted screw, remove the rear output seal. Installation INSTALLATION 1. Clean fluid residue from sealing surface and inspect for defects. 2. Using Seal Installer D-163 (2) and Universal Handle C-4171 (1), install seal in the rear case half. 3. Install propeller shaft. 4. Verify proper transfer case fluid level. 5. Lower vehicle. Removal REMOVAL 1. Remove the front propeller shaft. 2. Remove the front propeller shaft seal boot (1) retaining clamp (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GENII Transfer Case > Page 10554 3. Remove the front propeller shaft seal boot (1). 4. Remove the front output shaft seal slinger (1) by bending (2) the slinger ears away from the transfer case. 5. Using a suitable pry tool (2), remove the slinger (1) from the output shaft using care not to damage the shaft. 6. Using a screw and a slide hammer, remove the front output shaft seal. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GENII Transfer Case > Page 10555 1. Install the new front output shaft seal with Seal Installer MB991168A. 2. Install the front output shaft seal slinger with Oil Slinger Installer 8840. Install the slinger onto the shaft until the tool contacts the rear of the output shaft. 3. Install a new seal boot clamp onto the seal boot. 4. Install the seal boot (1) and clamp onto the slinger hub and tighten the clamp with Axle Clamp Installer C-4975A. 5. Install front propeller shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GENII Transfer Case > Page 10556 Seals and Gaskets: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Remove rear propeller shaft. 3. Using a suitable pry tool or slide-hammer mounted screw, remove the extension housing seal. Installation INSTALLATION 1. Clean fluid residue from sealing surface and inspect for defects. 2. Using Seal Installer D-163 (2) and Universal Handle C-4171 (1), install seal in extension housing. 3. Install propeller shaft. 4. Verify proper transfer case fluid level. 5. Lower vehicle. Removal REMOVAL 1. Remove the front propeller shaft. 2. Remove the front propeller shaft seal boot (1) retaining clamp (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GENII Transfer Case > Page 10557 3. Remove the front propeller shaft seal boot (1). 4. Remove the front output shaft seal slinger (1) by bending (2) the slinger ears away from the transfer case. 5. Using a suitable pry tool (2), remove the slinger (1) from the output shaft using care not to damage the shaft. 6. Using a screw and a slide hammer, remove the front output shaft seal. Installation INSTALLATION 1. Install the new front output shaft seal with Seal Installer MB991168A. 2. Install the front output shaft seal slinger with Oil Slinger Installer 8840. Install the slinger onto the shaft until the tool contacts the rear of the output shaft. 3. Install a new seal boot clamp onto the seal boot. 4. Install the seal boot and clamp onto the slinger hub and tighten the clamp with Axle Clamp Installer C-4975A. 5. Install front propeller shaft. Removal REMOVAL 1. Raise and support vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GENII Transfer Case > Page 10558 2. Remove rear propeller shaft. 3. Using a suitable pry tool or slide-hammer mounted screw, remove the extension housing seal. Installation INSTALLATION 1. Clean fluid residue from sealing surface and inspect for defects. 2. Using Seal Installer D-163 (2) and Universal Handle C-4171 (1), install seal in extension housing. 3. Install propeller shaft. 4. Verify proper transfer case fluid level. 5. Lower vehicle. Removal REMOVAL 1. Remove the front propeller shaft. 2. Remove the front propeller shaft seal boot (1) retaining clamp (2). 3. Remove the front propeller shaft seal boot (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GENII Transfer Case > Page 10559 4. Remove the front output shaft seal slinger (1) by bending (2) the slinger ears away from the transfer case. 5. Using a suitable pry tool (2), remove the slinger (1) from the output shaft using care not to damage the shaft. 6. Using a screw and a slide hammer, remove the front output shaft seal. Installation INSTALLATION 1. Install the new front output shaft seal with Seal Installer MB991168A. 2. Install the front output shaft seal slinger with Oil Slinger Installer 8840. Install the slinger onto the shaft until the tool contacts the rear of the output shaft. 3. Install a new seal boot clamp onto the seal boot. 4. Install the seal boot and clamp onto the slinger hub and tighten the clamp with Axle Clamp Installer C-4975A. 5. Install front propeller shaft. Removal REMOVAL 1. Raise and support vehicle. 2. Remove rear propeller shaft. 3. Using a suitable pry tool or slide-hammer mounted screw, remove the extension housing seal. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GENII Transfer Case > Page 10560 1. Clean fluid residue from sealing surface and inspect for defects. 2. Using Seal Installer D-163 (2) and Universal Handle C-4171 (1), install seal in extension housing. 3. Install propeller shaft. 4. Verify proper transfer case fluid level. 5. Lower vehicle. Removal REMOVAL 1. Remove the front propeller shaft. 2. Remove the front propeller shaft seal boot retaining clamp (2). 3. Remove the front propeller shaft seal boot (1) from the front output shaft seal slinger (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GENII Transfer Case > Page 10561 4. Remove the front output shaft seal slinger (1) by bending the slinger away (2) from the transfer case. 5. Using a suitable pry tool, remove the slinger from the output shaft using care not to damage the shaft. 6. Using a screw and a slide hammer, remove the front output shaft seal. Installation INSTALLATION 1. Install the new front output shaft seal with Seal Installer MB991168A. 2. Install the front output shaft seal slinger with Oil Slinger Installer 8840. Install the slinger onto the shaft until the tool contacts the rear of the output shaft. 3. Install a new seal boot clamp onto the seal boot. 4. Install the seal boot and clamp onto the slinger hub and tighten the clamp with Axle Clamp Installer C-4975A. 5. Install front propeller shaft. Removal REMOVAL 1. Raise and support vehicle. 2. Remove rear propeller shaft. 3. Using a suitable pry tool or slide-hammer mounted screw, remove the rear output seal. Installation INSTALLATION 1. Clean fluid residue from sealing surface and inspect for defects. 2. Using Seal Installer D-163 (2) and Universal Handle C-4171 (1), install seal in the rear case half. 3. Install propeller shaft. 4. Verify proper transfer case fluid level. 5. Lower vehicle. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GENII Transfer Case > Page 10562 1. Remove the front propeller shaft. 2. Remove the front propeller shaft seal boot (1) retaining clamp (2). 3. Remove the front propeller shaft seal boot (1). 4. Remove the front output shaft seal slinger (1) by bending (2) the slinger ears away from the transfer case. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GENII Transfer Case > Page 10563 5. Using a suitable pry tool (2), remove the slinger (1) from the output shaft using care not to damage the shaft. 6. Using a screw and a slide hammer, remove the front output shaft seal. Installation INSTALLATION 1. Install the new front output shaft seal with Seal Installer MB991168A. 2. Install the front output shaft seal slinger with Oil Slinger Installer 8840. Install the slinger onto the shaft until the tool contacts the rear of the output shaft. 3. Install a new seal boot clamp onto the seal boot. 4. Install the seal boot (1) and clamp onto the slinger hub and tighten the clamp with Axle Clamp Installer C-4975A. 5. Install front propeller shaft. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GENII Transfer Case > Page 10564 1. Raise and support vehicle. 2. Remove rear propeller shaft. 3. Use a suitable chisel or pry tool to remove the rear extension housing dust boot (2). 4. Use a suitable chisel or pry tool to remove the rear extension housing seal. Installation INSTALLATION 1. Clean fluid residue from sealing surface and inspect for defects. 2. Install the extension housing dust boot and seal assembly with Seal Installer 9037 (3) and Universal Handle C-4171 (2). 3. Install propeller shaft. 4. Verify proper transfer case fluid level. 5. Lower vehicle. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GENII Transfer Case > Page 10565 1. Remove the front propeller shaft. 2. Install two bolts 180° apart into the front output shaft companion flange. 3. Place Yoke Holder 6719 (1) over the bolts (2) and against the companion flange. 4. Remove and discard the front companion flange nut. 5. Remove the companion flange from the front output shaft. It may be necessary to use Pinion Flange Remover 8992 to remove the companion flange. 6. Using a screw and a slide hammer, remove the front output shaft seal. Installation INSTALLATION 1. Install the new front output shaft seal with Seal Installer MB991168A. 2. Install the front companion flange onto the front output shaft. 3. Install two bolts 180° apart into the front output shaft companion flange. 4. Place Yoke Holder 6719 (1) over the bolts (2) and against the companion flange. 5. Install a new front companion flange nut. Tighten the companion flange nut to 176-271 Nm (130-200 ft.lbs.). 6. Install front propeller shaft. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GENII Transfer Case > Page 10566 1. Raise and support vehicle. 2. Remove rear propeller shaft. 3. Use a suitable chisel or pry tool to remove the rear extension housing dust boot (2). 4. Use a suitable chisel or pry tool to remove the rear extension housing seal. Installation INSTALLATION 1. Clean fluid residue from sealing surface and inspect for defects. 2. Install the extension housing dust boot and seal assembly with Seal Installer 9037 (3) and Universal Handle C-4171 (2). 3. Install propeller shaft. 4. Verify proper transfer case fluid level. 5. Lower vehicle. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > NV241 GENII Transfer Case > Page 10567 1. Remove the front propeller shaft. 2. Install two bolts 180° apart into the front output shaft companion flange. 3. Place Yoke Holder 6719 (1) over the bolts (2) and against the companion flange. 4. Remove and discard the front companion flange nut. 5. Remove the companion flange from the front output shaft. It may be necessary to use Pinion Flange Remover 8992 to remove the companion flange. 6. Using a screw and a slide hammer, remove the front output shaft seal. Installation INSTALLATION 1. Install the new front output shaft seal with Seal Installer MB991168A. 2. Install the front companion flange onto the front output shaft. 3. Install two bolts 180° apart into the front output shaft companion flange. 4. Place Yoke Holder 6719 (1) over the bolts (2) and against the companion flange. 5. Install a new front companion flange nut. Tighten the companion flange nut to 176-271 Nm (130-200 ft.lbs.). 6. Install front propeller shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Component ID: 491 Component : SWITCH-TRANSFER CASE SELECTOR Connector: Name : SWITCH-TRANSFER CASE SELECTOR Color : BLACK # of pins : 10 Qualifier : (ETC) Pin Description Circuit 1 TRANSFER CASE POSITION SENSOR INPUT K77 20BR/WT 2-3 MODE SELECT K977 20BR/WT 4 PANEL LAMPS CONTROL E11 20OR/DB 5 GROUND Z905 20BK 6 NEUTRAL INDICATOR G95 20VT/BR 7 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 8-9-10 - Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 10572 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 10573 Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 10574 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 10575 Four Wheel Drive Selector Switch: Diagrams Component ID: 491 Component : SWITCH-TRANSFER CASE SELECTOR Connector: Name : SWITCH-TRANSFER CASE SELECTOR Color : BLACK # of pins : 10 Qualifier : (ETC) Pin Description Circuit 1 TRANSFER CASE POSITION SENSOR INPUT K77 20BR/WT 2-3 MODE SELECT K977 20BR/WT 4 PANEL LAMPS CONTROL E11 20OR/DB 5 GROUND Z905 20BK 6 NEUTRAL INDICATOR G95 20VT/BR 7 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 8-9-10 - Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 10576 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 10577 Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 10578 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case Four Wheel Drive Selector Switch: Description and Operation NV243 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 10581 For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere, is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 10582 Four Wheel Drive Selector Switch: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: - the AWD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 10583 The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 10584 Four Wheel Drive Selector Switch: Description and Operation NV246 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: - the AWD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 10585 For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 10586 Four Wheel Drive Selector Switch: Description and Operation NV273 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 10587 For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor Gear Sensor/Switch: Locations Assembly-Shift Motor/Mode Sensor Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10592 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10593 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10594 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10595 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10596 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10597 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10598 Gear Sensor/Switch: Locations Sensor-Transfer Case Position Component ID: 429 Component : SENSOR-TRANSFER CASE POSITION Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC) Pin Description Circuit 1 MODE SENSOR A D201 20WT/DG Pin Description Circuit 1 MODE SENSOR A D201 18WT/DG 2 GROUND Z955 20BK 2 GROUND Z955 18BK 2 GROUND Z901 20BK Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10599 Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 10600 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor Gear Sensor/Switch: Diagrams Assembly-Shift Motor/Mode Sensor Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10603 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10604 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10605 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10606 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10607 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10608 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10609 Gear Sensor/Switch: Diagrams Sensor-Transfer Case Position Component ID: 429 Component : SENSOR-TRANSFER CASE POSITION Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC) Pin Description Circuit 1 MODE SENSOR A D201 20WT/DG Pin Description Circuit 1 MODE SENSOR A D201 18WT/DG 2 GROUND Z955 20BK 2 GROUND Z955 18BK 2 GROUND Z901 20BK Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10610 Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 10611 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case Gear Sensor/Switch: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10614 Mode Sensor Channel States Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10615 Gear Sensor/Switch: Description and Operation NV246 Transfer Case Description DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The FCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Front Control Module (FCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to for the sensor codes returned to the FCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angle Vs. Transfer Case Position Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10616 Mode Sensor Channel States Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10617 Gear Sensor/Switch: Description and Operation NV271 Transfer Case Description DESCRIPTION The transfer case position sensor is an electronic device whose output can be interpreted to indicate the transfer case's current operating mode. The sensor consists of a five position, resistive multiplexed circuit which returns a specific resistance value to the Powertrain Control Module (PCM) for each transfer case operating mode. The sensor is located on the top of the transfer case, just left of the transfer case centerline and rides against the sector plate roostercomb. The PCM supplies 5VDC (+/- 0.5V) to the sensor and monitors the return voltage to determine the sector plate, and therefore the transfer case, position. Operation OPERATION Operating Mode Versus Resistance Position Sensor Linear Movement Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10618 During normal vehicle operation, the Powertrain Control Module (PCM) monitors the transfer case position sensor return voltage to determine the operating mode of the transfer case. Refer to the Operating Mode Versus Resistance table for the correct resistance for each position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10619 Gear Sensor/Switch: Description and Operation NV243 Transfer Case Description DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10620 Mode Sensor Channel States Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10621 Gear Sensor/Switch: Description and Operation NV273 Transfer Case Description DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 10622 Mode Sensor Channel States Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Removal Gear Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Disengage the transfer case position sensor connector from the position sensor. 3. Remove the position sensor from the transfer case. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Removal > Page 10625 Gear Sensor/Switch: Service and Repair Installation INSTALLATION 1. Inspect the O-ring seal on the transfer case position sensor. Replace the O-ring if necessary. 2. Install the transfer case position sensor into the transfer case. Torque the sensor to 27 Nm (20 ft.lbs.). 3. Engage the transfer case position sensor connector to the position sensor. 4. Lower vehicle. 5. Verify proper sensor operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front Speed Sensor: Locations Sensor-Prop Shaft Speed-Front Component ID: 420 Component : SENSOR-PROP SHAFT SPEED-FRONT Connector: Name : SENSOR-PROP SHAFT SPEED-FRONT Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR 2 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 10630 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 10631 Speed Sensor: Locations Sensor-Prop Shaft Speed-Rear Component ID: 421 Component : SENSOR-PROP SHAFT SPEED-REAR Connector: Name : SENSOR-PROP SHAFT SPEED-REAR Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 2 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 10632 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front Speed Sensor: Diagrams Sensor-Prop Shaft Speed-Front Component ID: 420 Component : SENSOR-PROP SHAFT SPEED-FRONT Connector: Name : SENSOR-PROP SHAFT SPEED-FRONT Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR 2 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 10635 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 10636 Speed Sensor: Diagrams Sensor-Prop Shaft Speed-Rear Component ID: 421 Component : SENSOR-PROP SHAFT SPEED-REAR Connector: Name : SENSOR-PROP SHAFT SPEED-REAR Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 2 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 10637 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Sensor-Output Shaft Speed-Front Speed Sensor: Service and Repair Sensor-Output Shaft Speed-Front Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connector from the front output shaft speed sensor (1). 3. Remove the front output shaft speed sensor from the transfer case. Installation INSTALLATION 1. Install the front output shaft speed sensor (1) into the transfer case. Tighten the speed sensor to 17 Nm (12.5 ft.lbs.). 2. Engage the wiring connector to the front output shaft speed sensor. 3. Lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Sensor-Output Shaft Speed-Front > Page 10640 Speed Sensor: Service and Repair Sensor-Output Shaft Speed-Rear Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connector from the rear output shaft speed sensor (1). 3. Remove the rear output shaft speed sensor from the transfer case. Installation INSTALLATION 1. Install the rear output shaft speed sensor (1) into the transfer case. Tighten the speed sensor to 17 Nm (12.5 ft.lbs.). 2. Engage the wiring connector to the rear output shaft speed sensor. 3. Lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Adjustments > NV241 GENII Transfer Case Shifter Transfer Case: Adjustments NV241 GENII Transfer Case ADJUSTMENT - SHIFT LEVER Transfer Case Shifter 1. Move shift lever into 2H position. 2. Raise vehicle. 3. Loosen shift rod lock bolt at trunnion. 4. Check shift rod fit in trunnion. Be sure rod does not bind in trunnion. Lubricate the shift rod and trunnion if necessary. 5. Verify that transfer case shift lever is in 2H detent position. The 2H detent position on the transfer case shift arm is the second position from full forward. 6. Align the adjustment locating hole on the lower shifter lever with the adjustment channel on the shifter bracket assembly. 7. Insert an appropriately sized pin through into the adjustment channel and through the locating hole to hold the shifter in the correct position. 8. Tighten shift rod lock bolt to 10 Nm (90 in. lbs.) torque. 9. Remove the locating pin from the adjustment channel and locating hole. 10. Check shift linkage operation. Be sure transfer case shifts into and operates properly in all ranges. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Adjustments > NV241 GENII Transfer Case > Page 10645 Shifter Transfer Case: Adjustments NV271 Transfer Case ADJUSTMENT - SHIFT LEVER Transfer Case Shifter 1. Move shift lever into 2H position. 2. Raise vehicle. 3. Loosen shift rod lock bolt at trunnion. 4. Check shift rod fit in trunnion. Be sure rod does not bind in trunnion. Lubricate the shift rod and trunnion if necessary. 5. Verify that transfer case shift lever is in 2H detent position. The 2H detent position on the transfer case shift arm is the second position from full forward. 6. Align the adjustment locating hole on the lower shifter lever with the adjustment channel on the shifter bracket assembly. 7. Insert an appropriately sized pin through into the adjustment channel and through the locating hole to hold the shifter in the correct position. 8. Tighten shift rod lock bolt to 10 Nm (90 in. lbs.) torque. 9. Remove the locating pin from the adjustment channel and locating hole. 10. Check shift linkage operation. Be sure transfer case shifts into and operates properly in all ranges. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Service and Repair > 4WD Floor Shift Boot Shifter Transfer Case: Service and Repair 4WD Floor Shift Boot Removal REMOVAL 1. Using a small flat-bladed tool, remove the insert (2) from the top of the shift knob (1). 2. Remove the nut (3) that secures the shift knob to the gear shift lever. 3. Remove the gear shift knob (2). 4. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the gear shift boot (3) to the floor console (1) and remove the boot. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Service and Repair > 4WD Floor Shift Boot > Page 10648 1. Position the gear shift boot (3) over the gear shift lever. 2. Engage the retaining tabs that secure the gear shift boot to the floor console (1). 3. Install the shift knob (2) over the gear shift lever. 4. Install the nut (3) that secures the shift knob (1) to the gear shift lever. Tighten the nut to 27 Nm (20 ft. lbs.). 5. Install the insert (2) into the top of the shift knob. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Service and Repair > 4WD Floor Shift Boot > Page 10649 Shifter Transfer Case: Service and Repair NV241 GENII Transfer Case Removal REMOVAL Transfer Case Shifter 1. Shift transfer case into 2H. 2. Raise and support the vehicle. 3. Loosen adjusting trunnion lock bolt and slide shift rod out of trunnion. If rod lacks enough travel to come out of trunnion, push trunnion out of shift lever. 4. Lower vehicle. 5. Remove transfer case shifter knob cap. 6. Remove nut holding shifter knob (2) to shift lever. 7. Remove shifter knob. 8. Remove the shift boot from the shifter console. 9. Remove the bolts securing the shifter mechanism to the floor pan. 10. Separate shift lever mechanism from the vehicle. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Service and Repair > 4WD Floor Shift Boot > Page 10650 Transfer Case Shifter 1. If the shifter mechanism does not have a adjustment locating pin installed, align the adjustment channel on the shifter assembly to the locating hole in the lower shift lever and install an appropriately sized pin to retain the position. 2. Position shift lever in vehicle. 3. Install the bolts to hold the shifter mechanism (4) to the floor pan. 4. Raise vehicle. 5. Verify that the transfer case is still in the 2H position. The 2H detent position on the transfer case shift arm is the second position from full forward. 6. Install trunnion to shift lever, if necessary. 7. Install shift rod to trunnion, if necessary. 8. Tighten the shift rod lock bolt to 10 Nm (90 in.lbs.). 9. Remove the shifter adjustment locating pin from the adjustment channel and the locating hole. 10. Lower vehicle. 11. Install the transfer case shifter console. 12. Install the shifter boot and the shifter knob onto the shifter lever. 13. Install nut to hold shifter knob to shift lever. 14. Install shifter knob cap. 15. Verify transfer case operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Service and Repair > 4WD Floor Shift Boot > Page 10651 Shifter Transfer Case: Service and Repair NV271 Transfer Case Removal REMOVAL Transfer Case Shifter 1. Shift transfer case into 2H. 2. Raise and support the vehicle. 3. Loosen adjusting trunnion lock bolt and slide shift rod out of trunnion. If rod lacks enough travel to come out of trunnion, push trunnion out of shift lever. 4. Lower vehicle. 5. Remove transfer case shifter knob cap. 6. Remove nut holding shifter knob (2) to shift lever. 7. Remove shifter knob. 8. Remove the shift boot from the shifter console. 9. Remove the bolts securing the shifter mechanism to the floor pan. 10. Separate shift lever mechanism from the vehicle. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Service and Repair > 4WD Floor Shift Boot > Page 10652 Transfer Case Shifter 1. If the shifter mechanism does not have a adjustment locating pin installed, align the adjustment channel on the shifter assembly to the locating hole in the lower shift lever and install an appropriately sized pin to retain the position. 2. Position shift lever in vehicle. 3. Install the bolts to hold the shifter mechanism (4) to the floor pan. 4. Raise vehicle. 5. Verify that the transfer case is still in the 2H position. The 2H detent position on the transfer case shift arm is the second position from full forward. 6. Install trunnion to shift lever, if necessary. 7. Install shift rod to trunnion, if necessary. 8. Tighten the shift rod lock bolt to 10 Nm (90 in.lbs.). 9. Remove the shifter adjustment locating pin from the adjustment channel and the locating hole. 10. Lower vehicle. 11. Install the transfer case shifter console. 12. Install the shifter boot and the shifter knob onto the shifter lever. 13. Install nut to hold shifter knob to shift lever. 14. Install shifter knob cap. 15. Verify transfer case operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front Speed Sensor: Locations Sensor-Prop Shaft Speed-Front Component ID: 420 Component : SENSOR-PROP SHAFT SPEED-FRONT Connector: Name : SENSOR-PROP SHAFT SPEED-FRONT Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR 2 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 10657 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 10658 Speed Sensor: Locations Sensor-Prop Shaft Speed-Rear Component ID: 421 Component : SENSOR-PROP SHAFT SPEED-REAR Connector: Name : SENSOR-PROP SHAFT SPEED-REAR Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 2 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 10659 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front Speed Sensor: Diagrams Sensor-Prop Shaft Speed-Front Component ID: 420 Component : SENSOR-PROP SHAFT SPEED-FRONT Connector: Name : SENSOR-PROP SHAFT SPEED-FRONT Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR 2 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 10662 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 10663 Speed Sensor: Diagrams Sensor-Prop Shaft Speed-Rear Component ID: 421 Component : SENSOR-PROP SHAFT SPEED-REAR Connector: Name : SENSOR-PROP SHAFT SPEED-REAR Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 2 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 10664 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Sensor-Output Shaft Speed-Front Speed Sensor: Service and Repair Sensor-Output Shaft Speed-Front Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connector from the front output shaft speed sensor (1). 3. Remove the front output shaft speed sensor from the transfer case. Installation INSTALLATION 1. Install the front output shaft speed sensor (1) into the transfer case. Tighten the speed sensor to 17 Nm (12.5 ft.lbs.). 2. Engage the wiring connector to the front output shaft speed sensor. 3. Lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Sensor-Output Shaft Speed-Front > Page 10667 Speed Sensor: Service and Repair Sensor-Output Shaft Speed-Rear Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connector from the rear output shaft speed sensor (1). 3. Remove the rear output shaft speed sensor from the transfer case. Installation INSTALLATION 1. Install the rear output shaft speed sensor (1) into the transfer case. Tighten the speed sensor to 17 Nm (12.5 ft.lbs.). 2. Engage the wiring connector to the rear output shaft speed sensor. 3. Lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Locations Transfer Case Actuator: Locations Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10671 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10672 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10673 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10674 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10675 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10676 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10677 Transfer Case Actuator: Diagrams Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10678 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10679 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10680 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10681 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10682 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10683 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case Transfer Case Actuator: Description and Operation NV243 Transfer Case Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 10686 torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 10687 Transfer Case Actuator: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 10688 Transfer Case Actuator: Description and Operation NV246 Transfer Case Description DESCRIPTION The shift motor consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Front Control Module (FCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 10689 Transfer Case Actuator: Description and Operation NV273 Transfer Case Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case Transfer Case Actuator: Service and Repair NV243 Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. Installation INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 10692 Transfer Case Actuator: Service and Repair NV244 GENII Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. Installation INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 10693 Transfer Case Actuator: Service and Repair NV246 Transfer Case Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Remove the front propeller shaft. 3. Disengage the wiring connectors from the shift motor and mode sensor. 4. Remove the bolts (1) holding the shift motor and mode sensor assembly (2) onto the transfer case. 5. Separate the shift motor and mode sensor assembly (1) from the transfer case. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 10694 6. Remove the shift motor isolator (1) from the transfer case (2). Installation INSTALLATION 1. Install the shift motor isolator (1) onto the transfer case (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 10695 NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Install the shift motor and mode sensor assembly (1) onto the transfer case. CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 3. Install the bolts (1) to hold the shift motor and mode sensor assembly (2) onto the transfer case. Tighten the bolts to 23.5 Nm (17 ft.lbs.). 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Install the front propeller shaft. 6. Refill the transfer case as necessary with the correct fluid for the application. 7. Lower vehicle and verify transfer case operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 10696 Transfer Case Actuator: Service and Repair NV273 Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. Installation INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Description Overdrive Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Description > Page 10704 Overdrive Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > Removal Overdrive Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > Removal > Page 10707 Overdrive Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid Pressure Regulating Solenoid: Locations Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 10712 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 10713 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 10714 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 10715 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 10716 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 10717 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 10718 Pressure Regulating Solenoid: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 10719 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid Pressure Regulating Solenoid: Diagrams Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 10722 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 10723 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 10724 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 10725 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 10726 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 10727 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 10728 Pressure Regulating Solenoid: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 10729 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Description Pressure Regulating Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Description > Page 10732 Pressure Regulating Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Removal Pressure Regulating Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Removal > Page 10735 Pressure Regulating Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Component ID: 440 Component : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Connector: Name : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Color : BLACK # of pins : 2 Pin Description Circuit 1 BTSI SOLENOID CONTROL K32 18DB/YL 2 GROUND Z101 18BK/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 10739 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 10740 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 10741 Shift Interlock Solenoid: Diagrams Component ID: 440 Component : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Connector: Name : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Color : BLACK # of pins : 2 Pin Description Circuit 1 BTSI SOLENOID CONTROL K32 18DB/YL 2 GROUND Z101 18BK/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 10742 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 10743 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid Shift Solenoid: Locations Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 10748 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 10749 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 10750 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 10751 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 10752 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 10753 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 10754 Shift Solenoid: Locations Assembly-Transmission Solenoid/Pressure Switch Component ID: 17 Component : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH Color : LT. BROWN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 OD SOLENOID CONTROL T60 20YL/GY 2 UD CONTROL T59 20YL/LB 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 2-4 SOLENOID CONTROL T19 18YL/DB 5 2-4 PRESSURE SWITCH SENSE T47 18YL/DG 6 OD PRESSURE SIGNAL T9 20DG/TN 7 L/R CONTROL T20 20DG/WT 8-9-10 L/R PRESSURE SIGNAL T50 20YL/TN Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 10755 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 10756 Shift Solenoid: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 10757 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid Shift Solenoid: Diagrams Assembly-Transmission Solenoid Component ID: 16 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2 5 VOLT SUPPLY F856 18YL/PK 3 SENSOR GROUND K900 20DB/DG 4 GOVERNOR PRESSURE SENSOR SIGNAL T38 18YL/BR 5 GOVERNOR PRESSURE SOLENOID CONTROL T118 18DG 6 3-4 SOLENOID CONTROL T9 18DG/TN 7 TORQUE CONVERTER CLUTCH SOLENOID CONTROL T75 18YL/LB 8 TRANSMISSION TEMPERATURE SIGNAL T54 18DG/OR Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 10760 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 10761 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 7 T806 20DG/VT 2 PRESSURE SIGNAL 5 T804 20YL/DB 3 TRANMISSION TEMPERATURE SIGNAL T54 20DG/OR 4 LINEAR 3 CONTROL T817 20YL/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 10762 5 LINEAR 1 CONTROL T813 20DG/LG 6 PRESSURE SIGNAL 8 T807 20DG/WT 7 PRESSURE SIGNAL 4 T803 20DG/BR 8 TEMPERATURE SENSOR GROUND T820 20YL/WT 9 LINEAR 3 GROUND T816 20YL/PK 10 LINEAR 1 GROUND T812 20DG/TN Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 10763 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Description Circuit 1 PRESSURE SIGNAL 1 T800 20DG/BR 2 PRESSURE SIGNAL 6 T805 20DG/OR 3 SHIFT 2 CONTROL T809 20DG/YL 4 SHIFT 4 CONTROL T811 20DG/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 10764 5 LINEAR 4 GROUND T818 20YL/OR 6 LINEAR 2 GROUND T814 20YL/BR 7 PRESSURE SIGNAL 2 T801 20DG/RD 8 PRESSURE SIGNAL 3 T802 20DG/PK 9 SHIFT 3 CONTROL T810 20DG/DB 10 SHIFT 1 CONTROL T808 20DG/GY 11 LINEAR 4 CONTROL T821 20YL/GY 12 LINEAR 2 CONTROL T815 20YL/RD Component Location - 20 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 10765 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 10766 Shift Solenoid: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 10767 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation > Description Shift Solenoid: Description and Operation Description DESCRIPTION SOLENOID AND PRESSURE SWITCH ASSEMBLY The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation > Description > Page 10770 Shift Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 68RFE Pressure Switch States A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Removal Shift Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Removal > Page 10773 Shift Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Description and Operation Throttle Valve Solenoid: Description and Operation DESCRIPTION On vehicles equipped with a Cummins diesel engine, the transmission throttle valve cable has been replace by the transmission throttle valve actuator (TTVA). The TTVA consists of an electric DC motor, two potentiometers, and a gear drive system. The TTVA is mechanically connected to the transmission throttle valve in the valve body by the "D" shaped opening in the bottom of the TTVA shaft. Changes in the TTVA position are therefore transferred to the throttle valve and cause changes in the transmission throttle pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Description and Operation > Page 10777 Throttle Valve Solenoid: Adjustments ADJUSTMENT The Transmission Throttle Valve Actuator (TTVA) does not require any mechanical adjustments. All changes in throttle valve position are controlled by the Engine Control Module (ECM). The TTVA does require an initialization period after the actuator has been removed or replaced. After the actuator has been removed or replaced, move the ignition to the ON position for thirty (30) seconds. This will allow the ECM sufficient time to perform the internal calibration procedures to learn the TTVA's current "zero" position. Once this is done, check the ECM for diagnostic trouble codes (DTCs). If no DTCs are set relating to the TTVA, the TTVA is fully calibrated and ready for use. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Service and Repair > Removal Throttle Valve Solenoid: Service and Repair Removal REMOVAL 1. Remove the bolts (2) holding the transmission throttle valve actuator (TTVA) (1) to the transmission case. 2. Allow the TTVA (1) to rotate clockwise away from the transmission. 3. Remove the wiring connector (2) from the TTVA (1). 4. Lift the TTVA (1) straight upward and off the throttle valve shaft (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Service and Repair > Removal > Page 10780 Throttle Valve Solenoid: Service and Repair Installation INSTALLATION 1. Position the transmission throttle valve actuator (TTVA) (1) over the throttle valve shaft (3). 2. Align the D-shaped opening in the bottom of the TTVA to the throttle valve shaft and install the TTVA onto the shaft. 3. Install the wiring connector (2) to the TTVA (1). 4. Rotate the TTVA (1) to the transmission case and install the bolts (2) to hold the TTVA to the transmission. 5. Tighten the bolts to 8.5 Nm (75 in.lbs.). 6. Initialize the TTVA. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal Actuator: Service and Repair Removal REMOVAL 1. Remove actuator wiring connector. 2. Remove actuator (1) bolts (2). 3. Remove actuator (1) from disconnect pocket (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal > Page 10786 Actuator: Service and Repair Installation INSTALLATION 1. Clean actuator (1) sealing surface and install new gasket (2) if necessary. 2. Align actuator shift fork (1) with disconnect collar (2) and install actuator on disconnect pocket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal > Page 10787 3. Install actuator (1) bolts (2) and tighten to 27 Nm (20 ft. lbs.). 4. Install disconnect actuator wiring connector. 5. Verify differential fluid level and add fluid if necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front Solenoid: Locations Module-Axle Disconnect-Front Component ID: 200 Component : MODULE-AXLE DISCONNECT-FRONT Connector: Name : MODULE-AXLE DISCONNECT-FRONT Color : DK. GRAY # of pins : 4 Qualifier : (LD 4WD) Pin Description Circuit 1 GROUND Z906 20BK 2 FRONT AXLE LOCK CONTROL G304 20VT/DB 3 FUSED B(+) A880 20DB/RD 4 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 35 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 10792 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 10793 Solenoid: Locations Solenoid-Locker-Front Component ID: 442 Component : SOLENOID-LOCKER-FRONT Connector: Name : SOLENOID-LOCKER-FRONT Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 FRONT LOCKER SOURCE T520 16YL/OR 2 LOCKER SENSOR SUPPLY T521 18YL/BK 3 FRONT LOCKER SENSOR SENSE T522 18YL/LB 4 FRONT LOCKER RETURN T524 16YL/LG Component Location - 36 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 10794 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 10795 Solenoid: Locations Solenoid-Locker-Rear Component ID: 443 Component : SOLENOID-LOCKER-REAR Connector: Name : SOLENOID-LOCKER-REAR Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 REAR LOCKER SOURCE T526 16YL/WT 2 LOCKER SENSOR SUPPLY T523 18YL/BK 3 REAR LOCKER SENSOR SENSE T527 18YL/TN 4 REAR LOCKER RETURN T528 16YL/GY Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 10796 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front Solenoid: Diagrams Module-Axle Disconnect-Front Component ID: 200 Component : MODULE-AXLE DISCONNECT-FRONT Connector: Name : MODULE-AXLE DISCONNECT-FRONT Color : DK. GRAY # of pins : 4 Qualifier : (LD 4WD) Pin Description Circuit 1 GROUND Z906 20BK 2 FRONT AXLE LOCK CONTROL G304 20VT/DB 3 FUSED B(+) A880 20DB/RD 4 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 35 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 10799 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 10800 Solenoid: Diagrams Solenoid-Locker-Front Component ID: 442 Component : SOLENOID-LOCKER-FRONT Connector: Name : SOLENOID-LOCKER-FRONT Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 FRONT LOCKER SOURCE T520 16YL/OR 2 LOCKER SENSOR SUPPLY T521 18YL/BK 3 FRONT LOCKER SENSOR SENSE T522 18YL/LB 4 FRONT LOCKER RETURN T524 16YL/LG Component Location - 36 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 10801 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 10802 Solenoid: Diagrams Solenoid-Locker-Rear Component ID: 443 Component : SOLENOID-LOCKER-REAR Connector: Name : SOLENOID-LOCKER-REAR Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Description Circuit 1 REAR LOCKER SOURCE T526 16YL/WT 2 LOCKER SENSOR SUPPLY T523 18YL/BK 3 REAR LOCKER SENSOR SENSE T527 18YL/TN 4 REAR LOCKER RETURN T528 16YL/GY Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 10803 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations Transfer Case Actuator: Locations Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10808 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10809 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10810 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10811 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10812 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10813 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10814 Transfer Case Actuator: Diagrams Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10815 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10816 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10817 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10818 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10819 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 10820 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case Transfer Case Actuator: Description and Operation NV243 Transfer Case Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 10823 torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 10824 Transfer Case Actuator: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 10825 Transfer Case Actuator: Description and Operation NV246 Transfer Case Description DESCRIPTION The shift motor consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Front Control Module (FCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 10826 Transfer Case Actuator: Description and Operation NV273 Transfer Case Description DESCRIPTION The shift motor (1) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case Transfer Case Actuator: Service and Repair NV243 Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. Installation INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 10829 Transfer Case Actuator: Service and Repair NV244 GENII Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. Installation INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 10830 Transfer Case Actuator: Service and Repair NV246 Transfer Case Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Remove the front propeller shaft. 3. Disengage the wiring connectors from the shift motor and mode sensor. 4. Remove the bolts (1) holding the shift motor and mode sensor assembly (2) onto the transfer case. 5. Separate the shift motor and mode sensor assembly (1) from the transfer case. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 10831 6. Remove the shift motor isolator (1) from the transfer case (2). Installation INSTALLATION 1. Install the shift motor isolator (1) onto the transfer case (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 10832 NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Install the shift motor and mode sensor assembly (1) onto the transfer case. CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 3. Install the bolts (1) to hold the shift motor and mode sensor assembly (2) onto the transfer case. Tighten the bolts to 23.5 Nm (17 ft.lbs.). 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Install the front propeller shaft. 6. Refill the transfer case as necessary with the correct fluid for the application. 7. Lower vehicle and verify transfer case operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 10833 Transfer Case Actuator: Service and Repair NV273 Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case. 4. Separate the shift motor and mode sensor assembly from the transfer case. Installation INSTALLATION 1. Verify that the shift sector O-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly onto the transfer case. 3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator Overdrive Indicator Lamp: Description and Operation Overdrive Off Indicator Description DESCRIPTION An overdrive off indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The overdrive off indicator consists of a stencil-like cutout of the text O/D OFF in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the overdrive off indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The overdrive off indicator is serviced as a unit with the instrument cluster. Operation OPERATION The overdrive off indicator gives an indication to the vehicle operator when the overdrive-OFF position of the tow/haul switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The overdrive off indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the overdrive off indicator for the following reasons: - Overdrive Off Indicator Lamp-On Message - Each time the cluster receives an electronic overdrive off indicator lamp-ON message from the PCM indicating that the overdrive-OFF position of the tow/haul switch has been selected, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the overdrive off indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the overdrive off indicator or the instrument cluster circuitry that controls the indicator, refer to Instrument Cluster/Carrier Testing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 10840 For proper diagnosis of the transmission control system, the PCM, the EMIC, the CAN data bus or the electronic communication related to overdrive off indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 10841 Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator Description DESCRIPTION A tow/haul indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The tow/haul indicator consists of a stencil-like cutout of the text TOW/HAUL in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the tow/haul indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The tow/haul indicator is serviced as a unit with the instrument cluster. Operation OPERATION The tow/haul indicator gives an indication to the vehicle operator when the tow/haul function of the tow/haul switch has been selected, revising the shift schedule of the electronically controlled automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The tow/haul indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the tow/haul indicator for the following reasons: - Tow/Haul Indicator Lamp-On Message - Each time the cluster receives an electronic tow/haul indicator lamp-ON message from the PCM indicating that the tow/haul shift schedule has been selected, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the tow/haul indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the tow/haul indicator or the instrument cluster circuitry that controls the indicator refer to Instrument Cluster / Carrier testing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 10842 For proper diagnosis of the transmission control system, the PCM, the EMIC, the CAN data bus or the electronic communication related to tow/haul indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description Temperature Warning Indicator - A/T: Description and Operation Description DESCRIPTION A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The transmission over-temperature indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Transmission Temperature in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The transmission over-temperature indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description > Page 10847 Temperature Warning Indicator - A/T: Description and Operation Operation OPERATION The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received over the Controller Area Network (CAN) data bus from the Powertrain Control Module (PCM). The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Indicator Lamp-On Message - Each time the cluster receives an electronic trans over-temp indicator lamp-ON message from the PCM indicating that the transmission fluid temperature is 135° C (275° F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the indicator is cycled OFF and then ON again by the appropriate lamp-ON and lamp-OFF messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the transmission over-temperature indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the instrument cluster illuminates the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission or the transmission cooling system are being overloaded, or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED,refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transmission temperature sensor, the PCM, the EMIC, the CAN data bus or the electronic communication related to transmission over-temperature indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description Four Wheel Drive Indicator Lamp: Description and Operation Description 4WD Auto Indicator 4WD AUTO INDICATOR A 4WD auto indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD auto indicator is located on the right side of the instrument cluster, to the right of the oil pressure gauge. The 4WD auto indicator consists of a stencil-like cutout of the text 4WD AUTO in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD auto indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD auto indicator is serviced as a unit with the instrument cluster. 4WD Indicator 4WD INDICATOR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 10853 A 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional four-wheel drive system, this indicator is electronically disabled. The 4WD indicator is located on the right side of the instrument cluster, to the right of the oil pressure gauge. The 4WD indicator consists of a stencil-like cutout of the text 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD indicator is serviced as a unit with the instrument cluster. 4WD Low Indicator 4WD LOW INDICATOR A 4WD low indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD low indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The 4WD low indicator consists of a stencil-like cutout of the text 4WD LOW in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD low indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD low indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 10854 Four Wheel Drive Indicator Lamp: Description and Operation Operation 4WD Auto Indicator 4WD AUTO INDICATOR The 4WD auto indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD auto mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD auto indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD auto indicator for the following reasons: - 4WD Auto Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD auto indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD auto indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD auto mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD auto indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD auto indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. 4WD Indicator 4WD INDICATOR The 4WD indicator gives an indication to the vehicle operator when the transfer case has been shifted into a 4WD mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD indicator for the following reasons: - 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly or the manual transfer case through the transfer case switch to determine when the 4WD mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the transfer case switch, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. 4WD Low Indicator 4WD LOW INDICATOR The 4WD low indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD low mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD low indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 10855 indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD low indicator for the following reasons: - 4WD Low Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD low indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD low indicator will be turned ON, then OFF again during the LED portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD low mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD low indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD low indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Description Malfunction Indicator Lamp - Transfer Case: Description and Operation Description DESCRIPTION A service 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The service 4WD indicator consists of a stencil-like cutout of the text SVC 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The service 4WD indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Description > Page 10860 Malfunction Indicator Lamp - Transfer Case: Description and Operation Operation OPERATION The service 4WD indicator gives an indication to the vehicle operator when the Totally Integrated Power Module (TIPM) has recorded a Diagnostic Trouble Code (DTC) for an electronic transfer case circuit or component malfunction. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the TIPM over the Controller Area Network (CAN) data bus. The service 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the service 4WD indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the service 4WD indicator is illuminated for about two seconds as a bulb test. - Service 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic service 4WD indicator lamp-ON message from the TIPM, the service 4WD indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the TIPM for 10 seconds the service 4WD indicator is illuminated by the cluster to indicate a loss of TIPM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the TIPM. - Actuator Test - Each time the cluster is put through the actuator test, the service 4WD indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case control circuits and transfer case shift motor/mode sensor assembly to determine the condition of the system. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the service 4WD indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the TIPM, the EMIC, the CAN data bus or the electronic communication related to service 4WD indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set Control Module: Customer Interest Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 10871 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 10872 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: Customer Interest A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 10877 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 10878 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set Control Module: Customer Interest A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 10883 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 10884 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 10885 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 10886 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set Control Module: All Technical Service Bulletins Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set NUMBER: 21-003-10 GROUP: Transmission DATE: May 12, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-019-08, DATED AUGUST 2, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination Due To Transmission Related DIG P0711 or P0776 OVERVIEW: This bulletin involves verifying software levels in the Transmission Control Module (1CM) and the Engine Control Module (ECM). Then, as necessary, selectively erasing and reprogramming the TCM and possibly the ECM. The ECM will need to be reprogrammed SEPARATELY if the ECM is not at the latest level. A related Labor operation is included if the ECM requires updating to perform the TCM flash. MODELS: 2007 (DC) Ram Truck (3500 Chassis Cab) NOTE: This bulletin applies to 2007 models equipped with a 6.7L turbo diesel engine and an AS68RC automatic transmission (sales code ETJ and DG3 respectively). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) due to one or both of the following Diagnostic Trouble Codes: 1. P0711 - Transmission Temperature Sensor / Performance. This condition may occur if the following sequence of events occur: a. The engine is cold soaked in an ambient temperature of 0°C (32°F) or lower. b. Then the engine is started and allowed to idle for about 10 minutes. c. Then the truck is driven into a warm environment with an ambient temperature greater than 0°C (32°F), and the engine is turned off. d. Upon restart of the engine, a MIL illumination may occur due to DTC P0711. 2. P0776 - Pressure Control Solenoid B Performance. DIAGNOSIS: Using a scan tool with the appropriate diagnostic procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is DTC P0711 or P0776 present? a. If YES >>> then perform the Repair Procedure. b. If NO >>> then STOP. This bulletin does not apply. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 10892 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Verify the ECM is at the latest software level. Is the ECM at the latest software level? a. Yes - Proceed to Step # 3. b. No - Proceed to Step # 2. 2. Reprogram the ECM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. 3. Reprogram the TCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 28 - DTC-Based Diagnostics> MODULE, Engine Control (ECM), 6.7L> Standard Procedure> PCM/ECM /TCM Programming. After ECM/TCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. 4. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-003-10 > May > 10 > Engine, A/T Controls - MIL ON/DTCs P0711/P0776 Set > Page 10893 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: All Technical Service Bulletins A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 10898 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 10899 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set Control Module: All Technical Service Bulletins A/T Controls - MIL ON/DTC P0868 Set NUMBER: 18-037-07 REV. A GROUP: Vehicle Performance DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-037-07, DATED MAY 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE IGNITION SWITCH POSITION WHEN PERFORMING SECTION A - TCM CIRCUIT TEST. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: 68RFE Transmission - DTC P0868 Low Line Pressure OVERVIEW: This bulletin involves checking the Transmission Control Module (TCM) to determine that it is in proper working order and then selectively erasing and reprogramming the TCM with new software. MODELS: 2007 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before April 30, 2007 (MDH 0430XX). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DIG) P0868 - Low Line Pressure This condition may be due to the Transmission Control Module (1CM) software or to a hardware circuit in the TCM. DIAGNOSIS: Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 10904 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: SECTION A - TCM CIRCUIT CHECK: 1. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 2. Disconnect and isolate the negative battery cable from the battery negative terminal. 3. Locate the TCM in the rear of the engine compartment. 4. Disconnect the "D" (green) electrical harness connector from the TCM. The "D" connector will have a green color stripe to identify it. 5. Install special tool 8815-1 (Adapter) to the TCM "D" connector. Connect the harness "D" connector to the 8815-1 Adapter. 6. Install special tool 8815 (PCM Diagnostic Pinout Box) to the 8815-1 Adapter. 7. Connect the negative battery cable to the battery. 8. Turn the ignition switch to the ** "OFF" ** position (the first detent clockwise from the ** "LOCK" ** position). DO NOT turn the ignition switch to the "ON/RUN" position, this will cause an incorrect voltage reading to be obtain when testing. NOTE: Verify that the ignition switch is in the ** "OFF" ** position and NOT in the "ON/RUN" position. The following steps must be followed in order. 9. Check of the D19 circuit: a. Set the DVOM to DC voltage. Adjust the DC volts to the appropriate setting to correctly read 12 volts. b. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 13 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 13, and the positive lead of the DVOM in pin 19. c. Pins 13 and 19 of the 8815 Pinout Box should connect to D13 (0 volts - ground) and to pins D19 (12 volts - switched battery voltage) of the TCM. d. Does the VOLT meter read 12 volts? e. If YES, then proceed to the next step. f. If NO, then further diagnosis of the circuit is required. 10. Check for a voltage difference between circuit D11 and D19: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 19 of the 8815 Pinout Box. Install the negative lead of the DVOM in pin 11, and the positive lead of the DVOM in pin 19. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 10905 b. Pins 11 and 19 of the 8815 Pinout Box should connect to pins D11 (12 volts - driver output voltage) and to D19 (12 volts - switched battery voltage) of the TCM. c. The VOLT meter should read LESS THAN 2 volts. There should not be more than a 2 volt difference between the two circuits (D11 and D19). d. If the volt meter reading is LESS THAN 2 volts, then proceed to Section B - Reprogram (Flash) The TCM. e. If the volt meter reading is GREATER THAN 2 volts, then proceed to the next step. 11. Turn the ignition switch to the ** "LOCK" ** position and remove the ignition key from the ignition switch. 12. Disconnect and isolate the negative battery cable from the battery negative terminal. 13. Disconnect the electrical harness "D" connector from the 8815-1 Adapter. The 8815-1 Adapter should now be connected only to the "D" connector of the TCM and to the 8815 Pinout Box. 14. Check for the resistance between circuit D11 and D13 in the TCM: a. Install the two leads of a known GOOD DVOM (Digital Volt Ohm Meter) to pins 11 and 13 of the 8815 Pinout Box. For this resistance test there is no difference/concern which lead of the DVOM is connected to which pin (11 or 13) b. Set the DVOM to OHM's. Adjust the ohm meter to the appropriate setting to correctly read 100,000 ohm (same as 100K ohm) resistance. c. Pins 11 and 13 of the 8815 Pinout Box should connect to pins D11 and to D13 of the TCM for this resistance test. d. For this test, if the circuit is good, the OHM meter should read GREATER THAN 100,000 ohm resistance (100K ohm). There should not be less than a 100,000 ohm resistance between the two circuits (D11 and D13). If the circuit is good, the technician will probably read a resistance of about 2,000,000 ohm (same as 2M ohm), significantly higher than the 100,000 ohm (100K ohm) cut point. e. If the ohm meter reading is GREATER THAN 100,000 ohm (100K ohm) resistance then the TCM is good. Proceed to Section B - Reprogram (Flash) The TCM. f. If ohm meter reading is LESS THAN 100,000 ohm (100K ohm) resistance, then the TCM is bad (circuit is shorted). Replace the TCM. If a new TCM is required, make sure the TCM software is at the latest revision level. 15. Connect the negative battery cable to the battery. NOTE: Additional circuit analysis and the replacement of the TCM under warranty is not addressed by this Service Bulletin and if required would be claimed separate to this bulletin. SECTION B - REPROGRAM (FLASH) TCM - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 10906 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU (TCM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the 1CM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". NOTE: Due to the ECU (TCM) programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM or TCM. 6. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 18-037-07A > Jul > 07 > A/T Controls - MIL ON/DTC P0868 Set > Page 10907 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10908 Control Module: Locations Component ID: 214 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2-3 POWER TAKEOFF RELAY ENABLE K427 18OR/LG 4-5 PRESSURE SIGNAL 4 T803 20DG/BR 6 PRESSURE SIGNAL 1 T800 20DG/BR 7-8-9-10 - 11 PRESSURE SIGNAL 5 T804 20YL/DB 12 PRESSURE SIGNAL 3 T802 20DG/PK 13 - 14 - 15 - 16 PRESSURE SIGNAL 6 T805 20DG/OR 17 PRESSURE SIGNAL 2 T801 20DG/RD Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10909 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Description Circuit 1 8 VOLT SUPPLY T72 20YL/DB 2 OUTPUT SPEED SIGNAL T14 20DG/BR 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10910 5-6-7 FUSED B(+) A104 20YL/RD 8 GROUND Z133 18BK/LG 9-10 - 11 - 12 - 13 - 14 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 15 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 16 TCC TEMPERATURE SIGNAL T819 20YL/VT 17 GROUND Z133 18BK/LG 18 - 19 SHIFT 4 CONTROL T811 20DG/LB 20 CAN C BUS (+) D65 20WT/LG 21 CAN C BUS (-) D64 20WT/LB 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10911 Pin Description Circuit 1 SHIFT 1 CONTROL T808 20DG/GY 2-3 SHIFT 3 CONTROL T810 20DG/DB 4-5 LINEAR 3 CONTROL T817 20YL/BR 6 LINEAR 1 GROUND T812 20DG/TN 7 LINEAR 1 CONTROL T813 20DG/LG 8 LINEAR 2 CONTROL T815 20YL/RD 9 LINEAR 2 GROUND T814 20YL/BR 10 PRESSURE SIGNAL 7 T806 20DG/VT 11 - 12 - 13 - 14 - - 15 LINEAR 3 GROUND T816 20YL/PK 16 TRS 1 SIGNAL T828 20DG/DB 17 TRS T42 SIGNAL T42 20DG/YL 18 TRS T3 SIGNAL T3 20DG/DB 19 TRS DRIVE SIGNAL T827 20DG/LB 20 TRS PARK SIGNAL T824 20YL/DB 21 TRS REVERSE SIGNAL T826 20DG/DB 22 SHIFT 2 CONTROL T809 20DG/YL 23 - 24 - 25 - 26 PRESSURE SIGNAL 8 T807 20DG/WT 27 - 28 TEMPERATURE SENSOR GROUND T820 20YL/WT 29 TRS NEUTRAL SIGNAL T825 20DG/YL 30 LINEAR 4 CONTROL T821 20YL/GY 31 LINEAR 4 GROUND T818 20YL/OR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10912 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10913 Control Module: Diagrams Component ID: 214 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2-3 POWER TAKEOFF RELAY ENABLE K427 18OR/LG 4-5 PRESSURE SIGNAL 4 T803 20DG/BR 6 PRESSURE SIGNAL 1 T800 20DG/BR 7-8-9-10 - 11 PRESSURE SIGNAL 5 T804 20YL/DB 12 PRESSURE SIGNAL 3 T802 20DG/PK 13 - 14 - 15 - 16 PRESSURE SIGNAL 6 T805 20DG/OR 17 PRESSURE SIGNAL 2 T801 20DG/RD Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10914 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Description Circuit 1 8 VOLT SUPPLY T72 20YL/DB 2 OUTPUT SPEED SIGNAL T14 20DG/BR 3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 4 TRANSMISSION CONTROL OUTPUT T16 16YL/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10915 5-6-7 FUSED B(+) A104 20YL/RD 8 GROUND Z133 18BK/LG 9-10 - 11 - 12 - 13 - 14 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 15 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR 16 TCC TEMPERATURE SIGNAL T819 20YL/VT 17 GROUND Z133 18BK/LG 18 - 19 SHIFT 4 CONTROL T811 20DG/LB 20 CAN C BUS (+) D65 20WT/LG 21 CAN C BUS (-) D64 20WT/LB 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10916 Pin Description Circuit 1 SHIFT 1 CONTROL T808 20DG/GY 2-3 SHIFT 3 CONTROL T810 20DG/DB 4-5 LINEAR 3 CONTROL T817 20YL/BR 6 LINEAR 1 GROUND T812 20DG/TN 7 LINEAR 1 CONTROL T813 20DG/LG 8 LINEAR 2 CONTROL T815 20YL/RD 9 LINEAR 2 GROUND T814 20YL/BR 10 PRESSURE SIGNAL 7 T806 20DG/VT 11 - 12 - 13 - 14 - - 15 LINEAR 3 GROUND T816 20YL/PK 16 TRS 1 SIGNAL T828 20DG/DB 17 TRS T42 SIGNAL T42 20DG/YL 18 TRS T3 SIGNAL T3 20DG/DB 19 TRS DRIVE SIGNAL T827 20DG/LB 20 TRS PARK SIGNAL T824 20YL/DB 21 TRS REVERSE SIGNAL T826 20DG/DB 22 SHIFT 2 CONTROL T809 20DG/YL 23 - 24 - 25 - 26 PRESSURE SIGNAL 8 T807 20DG/WT 27 - 28 TEMPERATURE SENSOR GROUND T820 20YL/WT 29 TRS NEUTRAL SIGNAL T825 20DG/YL 30 LINEAR 4 CONTROL T821 20YL/GY 31 LINEAR 4 GROUND T818 20YL/OR Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 10917 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description Control Module: Description and Operation Description DESCRIPTION On gasoline vehicles the Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). 68RFE TCM LOCATION Vehicles equipped 68RFE transmission and a 6.7L Diesel engine, the TCM is housed in the NGC4 controller utilizing only the C1 and C4 connectors (TCM only). The controller is located at the rear of the engine compartment, near the right inner fender. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 10920 AS68RC TCM LOCATION On Cab Chassis models equipped with the AS68RC transmission the Transmission Control Module (TCM) has three electrical connectors and is located in the passenger compartment underneath of the left side of the dash panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 10921 Control Module: Description and Operation Operation OPERATION RLE and RFE TRANSMISSIONS The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) (if equipped) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 10922 An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 10923 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 10924 SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 10925 AISIN AS68RC TRANSMISSION The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Speed Sensor - Output Speed Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Description > Page 10926 - Manifold Pressure - Throttle position - Torque Reduction Confirmation - Engine Coolant Temperature - Exhaust Brake Status (if equipped) - PTO Request (if equipped) - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Exhaust Brake Cut Request (if equipped). - Solenoids. - Torque Reduction Request. Some examples of TCM .indirect outputs are: - Transmission Temperature (to PCM). - PRNDL Position (to cluster/CCN). - PTO Status. In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI). - Storing and selecting appropriate Shift Schedules. - System self-diagnostics. - Diagnostic capabilities (with scan tool). Clutch filling time is continuously maintained when the vehicle is running. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10931 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10932 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10933 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10934 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10935 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10936 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10937 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10938 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10939 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10940 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10941 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10942 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10943 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10944 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10945 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10946 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10947 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10948 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 10949 Transmission Control System Relay: Connector Views Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > AS68RC Automatic Transmission Transmission Control System Relay: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION AS68RC Automatic Transmission NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. The relay is supplied fused B+ voltage, energized by the TIPM, and is used to supply power to the TCM when the transmission is in normal operating mode. Operation OPERATION The TIPM energizes the transmission control relay. When the relay is "off", no power is supplied to the TCM and the transmission will not operate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Control Module: Locations Component ID: 204 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 LOCKER SENSOR SUPPLY T521 20YL/BK A2 LOCKER SWITCH SUPPLY T537 20YL/LG A3 LOCKER SENSOR SUPPLY T523 20YL/BK A4 - A5 - A6 CAN C BUS (+) D65 20WT/LG A7 CAN C BUS (-) D64 20WT/LB A8 REAR LOCKER SENSOR SENSE T527 20YL/TN A9 FRONT LOCKER SENSOR SENSE T522 20YL/LB A10 LOCKER SWITCH SENSE T535 20YL/BR A11 - A12 - A13 - A14 - B FUSED B(+) A121 14RD/YL B1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG B2 SWITCH SUPPLY T536 20YL/WT B3 - B4 - B5 STABILIZER BAR SWITCH SENSE T531 20YL/TN B6 LOCKER OPEN ILLUMINATION SENSE T532 20YL/GY B7 LOCKER REAR ILLUMINATION SENSE T533 20YL/LB B8 LOCKER FR/RR ILLUMINATION SENSE T534 20YL B9 STABILIZER BAR DISENGAGE ILLUMINATION SENSE T530 20YL/DG B10 STABILIZER BAR ENGAGE ILLUMINATION SENSE T529 20YL/LG B11 - B12 - B13 - B14 - C FRONT LOCKER SOURCE T520 16YL/OR C1 - C2 - C3 - C4 - C5 - - Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 10956 C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - D REAR LOCKER SOURCE T526 16YL/WT E GROUND Z935 16BK F GROUND Z935 16BK G FRONT LOCKER RETURN T524 16YL/LG H REAR LOCKER RETURN T528 16YL/GY Component Location - 29 Component Location - 28 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 10957 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 10958 Control Module: Diagrams Component ID: 204 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 LOCKER SENSOR SUPPLY T521 20YL/BK A2 LOCKER SWITCH SUPPLY T537 20YL/LG A3 LOCKER SENSOR SUPPLY T523 20YL/BK A4 - A5 - A6 CAN C BUS (+) D65 20WT/LG A7 CAN C BUS (-) D64 20WT/LB A8 REAR LOCKER SENSOR SENSE T527 20YL/TN A9 FRONT LOCKER SENSOR SENSE T522 20YL/LB A10 LOCKER SWITCH SENSE T535 20YL/BR A11 - A12 - A13 - A14 - B FUSED B(+) A121 14RD/YL B1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG B2 SWITCH SUPPLY T536 20YL/WT B3 - B4 - B5 STABILIZER BAR SWITCH SENSE T531 20YL/TN B6 LOCKER OPEN ILLUMINATION SENSE T532 20YL/GY B7 LOCKER REAR ILLUMINATION SENSE T533 20YL/LB B8 LOCKER FR/RR ILLUMINATION SENSE T534 20YL B9 STABILIZER BAR DISENGAGE ILLUMINATION SENSE T530 20YL/DG B10 STABILIZER BAR ENGAGE ILLUMINATION SENSE T529 20YL/LG B11 - B12 - B13 - B14 - C FRONT LOCKER SOURCE T520 16YL/OR C1 - C2 - C3 - C4 - C5 - - Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 10959 C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - D REAR LOCKER SOURCE T526 16YL/WT E GROUND Z935 16BK F GROUND Z935 16BK G FRONT LOCKER RETURN T524 16YL/LG H REAR LOCKER RETURN T528 16YL/GY Component Location - 29 Component Location - 28 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 10960 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description Control Module: Description and Operation Description DESCRIPTION The Transfer Case Control Module (TCCM) functionality now resides in the Totally Integrated Power Module (TIPM), refer to the TIPM information for location. The TIPM controls the 4X4 transfer case shift functions via the actuation of a shift motor and utilizing the feedback of a mode sensor assembly. Communication is via the CAN bus. Inputs include user selectable 4X4 modes that include 2WD, AWD, 4HI, 4LO, and Neutral (selections vary with the specific transfer case). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 10963 Control Module: Description and Operation Operation OPERATION The Transfer Case Control Module (TCCM) functionality in the Totally Integrated Power Module (TIPM) utilizes the input from the transfer case mounted mode sensor, the instrument panel mounted selector switch, and the following information from the vehicle's CAN bus to determine if a shift is allowed. - Engine RPM and Vehicle Speed - Diagnostic Requests - Manual Transmission and Brake Applied - PRNDL - Ignition Status - ABS Messages Once the TIP determines that a requested shift is allowed, it actuates the bi-directional shift motor as necessary to achieve the desired transfer case operating mode. The TIPM also monitors the mode sensor while controlling the shift motor to determine the status of the shift attempt. Several items can cause the requested shift not to be completed. If the TIPM has recognized a fault (DTC) of some variety, it will begin operation in one of four Functionality Levels. These levels are: - Level Zero - Normal Operation. - Level One - Only Mode Shifts Are Allowed. - Level Two - Only Mode Shifts and Shifts Into LOW Are Allowed (No Neutral Shifts Are Allowed). - Level Three - No Shifts Are Allowed The TIPM can also be operating in one of three possible power modes. These power modes are: - Full Power Mode is the normal operational mode of the module. This mode is achieved by normal CAN bus traffic being present and the ignition being in the RUN position. Reduced Power Mode will be entered when the ignition has been powered off. In this state, the module will shut down power supplied to external devices, and to electronic interface inputs and outputs. From this state the module can enter either Sleep Mode or Full Power Mode. To enter this mode, the module must receive an ignition message denoting that the ignition is off, or not receive any messages for 5 ± 0.5 seconds. To exit this mode, the module must receive one ignition message that denotes that the ignition is in the RUN position. - Sleep Mode will be entered, from the Reduced Power Mode, when no CAN traffic has been sensed for 20 ± 1 seconds. If during Sleep Mode the module detects CAN bus traffic, it will revert to the Reduced Power mode while monitoring for ignition messages. It will remain in this state as long as there is traffic other than run or start messages, and will return to Sleep mode if the bus goes without traffic for 20 ± 1 seconds. SHIFT REQUIREMENTS If the TIPM is in full power mode and at functionality level zero, it uses the following criteria to determine if a shift is allowed. If any of the driver controllable conditions are not met once the shift request is recognized, the TIPM will solidly illuminate the source position's LED and flash the desired position's LED for all shifts except NEUTRAL. The NEUTRAL shift LED strategy will be discussed later. Mode shifts will be allowed regardless of transmission gear or vehicle speed, whenever the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - A change in the Selector switch state indicates that a mode shift has been requested. - A valid mode sensor signal is being sensed by the TIPM. - Proper transmit/receive messages are occurring on the CAN bus. - Ignition key switch is in the RUN position. Range shifts will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - A change in the Selector Switch state indicating a range shift has been requested. - Transmission in NEUTRAL signal must be recognized for at least 1.5 seconds ± 100 msec. (Automatic transmissions only) - Proper transmit/receive messages are occurring on the CAN bus. - Clutch signal is recognized for 500 msec ± 50 msec (Manual transmissions only). - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position. - A valid mode sensor signal is being sensed by the TIPM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 10964 A shift into transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 4.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus. (Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the CAN bus. - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position, engine off. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TIPM. A shift out of transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 1.0 seconds ± 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus.(Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the CAN bus. - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TIPM. SHIFT SEQUENCES Once all the driver controllable conditions for the requested shift have been met, the TIPM begins a shift timer with a maximum duration of 1 second per 'D' channel transition. If the shift timer expires before the TIPM recognizes to correct mode sensor code, the shift is considered to have been blocked. The blocked shift will increment the blocked shift counter by one. The TIPM strategy for handling blocked shifts will be described later. The process the TIPM performs for the various shifts will be described first. RANGE AND MODE SHIFTS The process for performing all the range and mode shifts are the same. The following steps describe the process. - Allow time for Selector Switch debounce; 250 msec ± 50 msec. - Extinguish the source gear's LED while flashing desired transfer case position's LED. - Engage the shift motor for a maximum of 1 second ± 100 msec per 'D' channel transition in the destination gear's direction while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Solidly illuminate the selected gear's LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds ± 100 msec. per 'D' channel. The TIPM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. The exception to the preceding sequence is when a shift from 4L to 2WD/AWD is requested. If 2WD/AWD is requested from the 4L position, the transfer case is first driven to the 4H position. If the 4H position is reached, the transfer case is then driven back to the 2WD/AWD position and the shift is considered complete. If the transfer case does not reach any the 4H position, but is in the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is also considered complete. SHIFT OUT OF NEUTRAL The following steps describe the process for a shift out of NEUTRAL. - Extinguish the Neutral LED. - Engage the shift motor for a maximum of 1 second ± 100 msec toward the transfer case 4H mode position while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Extinguish the Neutral LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ± 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds 100 msec. The Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 10965 TIPM waits for 2.0 seconds ± 50 msec. and repeats the attempt to shift to the desired position. - When the Neutral button is released, if the 4H position is the desired position, the shift is complete. Illuminate the 4H LED. - Otherwise when the Neutral button is released, if all of the shift requirements are being met then engage the shift motor towards the desired position for 1 second ± 100 msec per 'D' channel. (if requirements for shifting are not met, illuminate the 4H LED and flash the destination LED as an indication to the driver that all of the driver controllable shift conditions are not being met). If this requires another range or mode shift, begin the range/mode shift process. - If the desired mode sensor code is not received after the shift timer expires (i.e. a blocked or other condition exists), refer to Blocked Shift Strategy. BLOCKED SHIFT STRATEGY When a shift is commanded, the shift motor will be driven towards its destination position, except in the case of shifting out of Neutral if 4L was selected (the transfer case will shift to the 4H position first, before proceeding to 4L). If the shift is blocked on the way to the destination, the TIPM may attempt to drive the motor back to the original position. This process will be allowed to occur 5 times. If the transfer case has reached a non-NEUTRAL 'D' channel during the shift re-attempts, the LED for the achieved gear position is illuminated and the shift attempts are stopped. To re-attempt the desired shift, the selector switch will need to be rotated to the current position until the switch debounce timer expires then a shift will need to be requested again. At the end of the 5th blocked attempt, the shift motor is driven towards the last known 'D' channel position. If this motor drive allows the transfer case to reach the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is considered complete and the shift attempts are ended. If the mode sensor is in the NEUTRAL region at the expiration of the shift timer, the TIPM will continue to make the shift attempts according to the blocked shift strategy independent of whether or not the driver controlled conditions are met. For shifts from NEUTRAL, if all 5 attempts fail to reach the desired position (which by default is 4H), the motor will be driven to stall in the direction of 4H or 4L, depending on the achieved position. If the transfer case has reached the 2WD/AWD or 4L between gear position nearest the NEUTRAL positions and the shift conditions are no longer being met, the transfer case will be driven toward the corresponding 'D' channel. Otherwise, the transfer case will be driven in the direction opposite the last attempt with the desired target being 4H or 4L. If the transfer case reaches the 2WD/AWD 'D' channel when being driven in the 4H direction, then one final 1.0 second drive toward 4H is attempted. If the transfer case then reaches any of the 4H positions, the shift is considered complete and the 4H LED is illuminated. If the transfer case is still the 2WD/AWD position, the shift is considered complete and the 2WD/AWD LED is illuminated. NOTE: If after the 5th blocked shift and reversal attempt, if the transfer case position is in the NEUTRAL region, shift attempts will continue until a non-NEUTRAL 'D' channel is reached. SHIFT REVERSAL TARGETS If the shift timer expires (1 second per 'D' channel) and the transfer case has not reached the desired position, all shifts will attempt to return to their original position with the exceptions of: - If the intended shift is going to the High rail from Low and can't make it, but it can make the 2WD/AWD position, the motor stops at that position. The TIPM will not attempt to cross back over NEUTRAL if it does not have to. This means that there was a block on the first attempt to go to 4H and the transfer case has made it through NEUTRAL to a known good position, then the motor will go back only to the 2WD/4WD position and execute the remainder of the attempts from there. - For shifts out of NEUTRAL, any time a shift is commanded out of NEUTRAL, the system needs to get out. The TIPM should never go to NEUTRAL unless the driver is commanding it and all required conditions are being met ENCODER DRIFT CORRECTION Whenever a shift is completed, the TIPM stores the position in memory as the transfer case's intended position. The TIPM continuously monitors the mode sensor and if the mode sensor drifts toward into a NEUTRAL region sensor position for 2.0 seconds, the TIPM will perform a motor drive to correct the drift. The transfer case will be driven toward the intended position for 1.0 seconds ± 100 msec. The TIPM will wait for 2.0 seconds ± 50 msec. and repeat the attempt to shift to the desired position. This will continue until the intended position is reached. SHIFT MOTOR BRAKING Two modes of shift motor braking are employed to improve shift performance, static and dynamic. Static shift motor braking is utilized under the following conditions: - Whenever the transfer case is in the 2WD/AWD or 4L 'D' channel position. - Whenever an invalid mode sensor code is present. Static motor braking is achieved by applying +12V on both shift motor wires. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 10966 NOTE: Static Shift Motor Braking is independent of ignition key position. SHIFT ATTEMPT LIMIT To protect the transfer case system, the TIPM will impose a limit on the number of shifts that can occur over a calibrated time period. The system will monitor the number of 'D' channel segment transitions that occur in any 30 second time period. If the number of segment transitions is 30 or greater, the system will go into a default mode. The default mode of operation for shifting is that the number of allowed 'D' channel transitions permitted to occur will be 3 over each 15 second ± 100 msec calibrated window of time. After 5 minutes ± 100 msec, the motor can be assumed to have cooled down and the system will revert to normal operation. The following rules also apply to the shift limit: - The attempt limit will not prevent shifts coming out of NEUTRAL, they will be allowed regardless of the counter/timer. - Any shift that is in progress when the counter reaches a maximum count in time will be allowed to complete before the default mode is entered. D-channel transitions during this period will not be counted towards the default mode limit. - A block, regardless of the direction, whether towards destination or back towards reversal target (shift timer expiring), will count as a value of 2 transitions towards the 30 segment transitions to go into default mode as defined above. Current attempt limit values are 30 transitions in 30 seconds and default mode values are 3 transitions every 15 seconds for 5 minutes. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Component ID: 410 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Description Circuit 1 SENSOR GROUND T160 20DG/WT Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 5 VOLT SUPPLY F856 20YL/PK 3 LINE PRESSURE SIGNAL T38 20YL/BR 4-- Component Location - 23 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 10972 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 10973 Fluid Pressure Sensor/Switch: Diagrams Component ID: 410 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Description Circuit 1 SENSOR GROUND T160 20DG/WT Pin Description Circuit 1 SENSOR GROUND K900 20DB/DG 2 5 VOLT SUPPLY F856 20YL/PK 3 LINE PRESSURE SIGNAL T38 20YL/BR 4-- Component Location - 23 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 10974 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description Fluid Pressure Sensor/Switch: Description and Operation Description DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, which is part of the pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the pump inlet. The system contains a Line Pressure Sensor, which is a direct input to the TCM. The line pressure sensor monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description > Page 10977 Fluid Pressure Sensor/Switch: Description and Operation Operation OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts, to ensure consistent shift quality. During all other operation, the desired line pressure value is adjusted based on torque level and other transmission requirements. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal Fluid Pressure Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal > Page 10980 Fluid Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Overdrive Switch: Locations Component ID: 490 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Description Circuit 123 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 4 GROUND Z71 20LB/BK 5 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 6 SENSOR GROUND T160 20DG/WT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 10984 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 10985 Overdrive Switch: Diagrams Component ID: 490 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Description Circuit 123 TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL T6 20DG 4 GROUND Z71 20LB/BK 5 AUTOSTICK (ERS)-TOW/HAUL SIGNAL T5 20DG/YL 6 SENSOR GROUND T160 20DG/WT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 10986 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 10987 Overdrive Switch: Testing and Inspection DIAGNOSIS AND TESTING - OVERDRIVE ELECTRICAL CONTROLS The tow/haul overdrive off switch, valve body solenoid, case connectors and related wiring can all be tested with a 12 volt test lamp or a volt/ohmmeter. Check continuity of each component when diagnosis indicates this is necessary. Switch and solenoid continuity should be checked whenever the transmission fails to shift into fourth gear range. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Switch: Service and Repair 42RLE Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 10990 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 10991 Overdrive Switch: Service and Repair 545RFE Automatic Transmission Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 10992 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 10993 Overdrive Switch: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 10994 and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 10995 Overdrive Switch: Service and Repair AS68RC Automatic Transmission Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 10996 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 11001 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 11002 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 11003 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 11004 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 11005 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 11006 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 11007 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 11008 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 11009 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 11010 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 11011 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 430 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Description Circuit 1 TRS NEUTRAL SIGNAL T825 20DG/YL 2 TRS T3 SIGNAL T3 20DG/DB 3 TRS 1 SIGNAL T828 20DG/DB 4 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 5 TRS PARK SIGNAL T824 20YL/DB 6 GROUND Z157 16BK/LG 7 TRS T42 SIGNAL T42 20DG/YL 8 TRS DRIVE SIGNAL T827 20DG/LB 9 TRS REVERSE SIGNAL T826 20DG/DB 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 11014 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 11015 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 11016 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Description Circuit 1-2 TRS SIGNAL T117 20DG/YL 3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 11017 5 TRS RETURN T917 20YL/TN 6 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 11018 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 11019 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Description Circuit 1 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 2-3 SENSOR GROUND K900 20DB/DG 4 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 11020 5-6-7 TRS T1 SIGNAL T1 20DG/LB 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T42 SIGNAL T42 20DG/YL 10 TRS T41 SIGNAL (P/N) T41 20YL/DB Component Location - 20 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 11021 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 11022 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 11023 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 18 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Description Circuit 1-2 L/R CONTROL T20 20DG/WT 3-4 TRS T41 SIGNAL (P/N) T41 20YL/DB 5 TRS T42 SIGNAL T42 20DG/YL 6-- 7 OD SOLENOID CONTROL T60 20YL/GY 8 TRS T3 SIGNAL T3 20DG/DB 9 TRS T1 SIGNAL T1 20DG/LB 10 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 11 4C PRESSURE SIGNAL T48 20BR/YL 12 LINE PRESSURE CONTROL T118 20DG 13 TRS T2 SIGNAL T4 20DG/LB 14 L/R PRESSURE SIGNAL T50 20DG/PK 15 2C PRESSURE SIGNAL T147 20DG/YL 16 OD PRESSURE SIGNAL T9 20DG/TN 17 UD CONTROL T59 20YL/LB 18 UD PRESSURE SIGNAL T29 20YL/WT 19 4C CONTROL T259 20YL/DG 20 2C CONTROL T219 20YL/LG 21 MS CONTROL T140 20YL/GY 22 SENSOR GROUND T160 20DG/WT 22 SENSOR GROUND K900 20DB/DG 23 TRANSMISSION TEMPERATURE SIGNAL T54 20DG/OR Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 11024 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 11027 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 11028 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 11029 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 11030 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 11031 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 11034 TRS REMOVAL/INSTALLATION 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 11035 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 11036 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 11037 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 11038 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed Transmission Speed Sensor: Locations Sensor-Input Speed Component ID: 405 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 11043 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 11044 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 11045 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 11046 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 11047 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 11048 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 11049 Transmission Speed Sensor: Locations Sensor-Output Speed Component ID: 415 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 11050 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 11051 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 11052 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 11053 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 18DG/BR 2 SPEED SENSOR GROUND T13 18DG/VT Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 11054 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 11055 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 11056 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 11057 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 11058 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 11059 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 11060 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 11061 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed Transmission Speed Sensor: Diagrams Sensor-Input Speed Component ID: 405 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 11064 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 11065 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 11066 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 INPUT SPEED SIGNAL T52 20DG/OR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 11067 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 11068 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 11069 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 11070 Transmission Speed Sensor: Diagrams Sensor-Output Speed Component ID: 415 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 8 VOLT SUPPLY T72 20YL/DB Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 11071 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 11072 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 11073 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 11074 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 18DG/BR 2 SPEED SENSOR GROUND T13 18DG/VT Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 11075 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 11076 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 11077 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 11078 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Description Circuit 1 OUTPUT SPEED SIGNAL T14 20DG/BR 2 SPEED SENSOR GROUND T13 20DG/VT Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 11079 Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 11080 Component Location - 19 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 11081 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 11082 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Speed Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The speed sensor (1) is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Operation OPERATION Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. Signals from this sensor are shared with the powertrain control module. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 11085 Transmission Speed Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 11086 Transmission Speed Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION INPUT AND OUTPUT SPEED SENSORS The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate DC square wave signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the "teeth" of the gear pass by the sensor coil, an DC square wave is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an DC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Transmission Speed Sensor: Service and Repair 68RFE Automatic Transmission Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the transmission case. Installation INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 11089 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. Installation INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 11090 Transmission Speed Sensor: Service and Repair AS68RC Automatic Transmission Output Speed Sensor OUTPUT SPEED SENSOR OUTPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor. 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. Input Speed Sensor INPUT SPEED SENSOR INPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 11091 3. Remove the wiring connector from the input speed sensor. 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. Output Speed Sensor OUTPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. OUTPUT SPEED SENSOR 1. Lubricate the output speed sensor O-ring with MOPAR(R) AS68RC ATF. 2. Install the output speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the wiring connector onto the output speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC ATF as necessary. Input Speed Sensor INPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 11092 INPUT SPEED SENSOR 1. Lubricate the output speed sensor O-ring with MOPAR(R) AS68RC ATF. 2. Install the input speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the electrical wiring connector onto the input speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC as necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Component ID: 431 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 TCC TEMPERATURE SIGNAL T819 20YL/VT 2 TEMPERATURE SENSOR GROUND T820 20YL/WT Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 11096 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 11097 Transmission Temperature Sensor/Switch: Diagrams Component ID: 431 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Description Circuit 1 TCC TEMPERATURE SIGNAL T819 20YL/VT 2 TEMPERATURE SENSOR GROUND T820 20YL/WT Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 11098 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection SWITCH-CLUTCH PEDAL POSITION 1. Disconnect switch 2-wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed - Continuity - Pedal Released - No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Description and Operation > Description Power Take-Off Switch: Description and Operation Description DESCRIPTION This Engine Control Module (ECM) input is used only on models equipped with aftermarket Power Take Off (PTO) units. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Description and Operation > Description > Page 11108 Power Take-Off Switch: Description and Operation Operation OPERATION This input is used only to tell the ECM that the aftermarket PTO (Power Take Off) unit has been engaged. The ECM will disable (temporarily shut down) certain OBD II diagnostic trouble codes when the PTO unit is engaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Component ID: 491 Component : SWITCH-TRANSFER CASE SELECTOR Connector: Name : SWITCH-TRANSFER CASE SELECTOR Color : BLACK # of pins : 10 Qualifier : (ETC) Pin Description Circuit 1 TRANSFER CASE POSITION SENSOR INPUT K77 20BR/WT 2-3 MODE SELECT K977 20BR/WT 4 PANEL LAMPS CONTROL E11 20OR/DB 5 GROUND Z905 20BK 6 NEUTRAL INDICATOR G95 20VT/BR 7 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 8-9-10 - Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 11113 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 11114 Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 11115 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 11116 Four Wheel Drive Selector Switch: Diagrams Component ID: 491 Component : SWITCH-TRANSFER CASE SELECTOR Connector: Name : SWITCH-TRANSFER CASE SELECTOR Color : BLACK # of pins : 10 Qualifier : (ETC) Pin Description Circuit 1 TRANSFER CASE POSITION SENSOR INPUT K77 20BR/WT 2-3 MODE SELECT K977 20BR/WT 4 PANEL LAMPS CONTROL E11 20OR/DB 5 GROUND Z905 20BK 6 NEUTRAL INDICATOR G95 20VT/BR 7 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 8-9-10 - Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 11117 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 11118 Component Location - 20 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 11119 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case Four Wheel Drive Selector Switch: Description and Operation NV243 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 11122 For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere, is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 11123 Four Wheel Drive Selector Switch: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: - the AWD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 11124 The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 11125 Four Wheel Drive Selector Switch: Description and Operation NV246 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: - the AWD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 11126 For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 11127 Four Wheel Drive Selector Switch: Description and Operation NV273 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: Selector Switch Interpretation Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 11128 For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor Gear Sensor/Switch: Locations Assembly-Shift Motor/Mode Sensor Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 11133 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 11134 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 11135 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 11136 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 11137 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 11138 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 11139 Gear Sensor/Switch: Locations Sensor-Transfer Case Position Component ID: 429 Component : SENSOR-TRANSFER CASE POSITION Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC) Pin Description Circuit 1 MODE SENSOR A D201 20WT/DG Pin Description Circuit 1 MODE SENSOR A D201 18WT/DG 2 GROUND Z955 20BK 2 GROUND Z955 18BK 2 GROUND Z901 20BK Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 11140 Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 11141 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor Gear Sensor/Switch: Diagrams Assembly-Shift Motor/Mode Sensor Component ID: 15 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A940 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 11144 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 11145 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 11146 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Description Circuit 1 5 VOLT SUPPLY T103 20YL/OR 2 MODE SENSOR A D201 20WT/DG 3 SENSOR RETURN G180 20VT/YL 4 SHIFT MOTOR CONTROL B T101 16DG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 11147 5 SHIFT MOTOR CONTROL A T102 16YL 6 FUSED B(+) A918 20RD 7 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 8-Component Location - 21 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 11148 Component Location - 26 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 11149 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 11150 Gear Sensor/Switch: Diagrams Sensor-Transfer Case Position Component ID: 429 Component : SENSOR-TRANSFER CASE POSITION Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC) Pin Description Circuit 1 MODE SENSOR A D201 20WT/DG Pin Description Circuit 1 MODE SENSOR A D201 18WT/DG 2 GROUND Z955 20BK 2 GROUND Z955 18BK 2 GROUND Z901 20BK Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 11151 Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 11152 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case Gear Sensor/Switch: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 11155 Mode Sensor Channel States Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 11156 Gear Sensor/Switch: Description and Operation NV246 Transfer Case Description DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The FCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Front Control Module (FCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to for the sensor codes returned to the FCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angle Vs. Transfer Case Position Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 11157 Mode Sensor Channel States Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 11158 Gear Sensor/Switch: Description and Operation NV271 Transfer Case Description DESCRIPTION The transfer case position sensor is an electronic device whose output can be interpreted to indicate the transfer case's current operating mode. The sensor consists of a five position, resistive multiplexed circuit which returns a specific resistance value to the Powertrain Control Module (PCM) for each transfer case operating mode. The sensor is located on the top of the transfer case, just left of the transfer case centerline and rides against the sector plate roostercomb. The PCM supplies 5VDC (+/- 0.5V) to the sensor and monitors the return voltage to determine the sector plate, and therefore the transfer case, position. Operation OPERATION Operating Mode Versus Resistance Position Sensor Linear Movement Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 11159 During normal vehicle operation, the Powertrain Control Module (PCM) monitors the transfer case position sensor return voltage to determine the operating mode of the transfer case. Refer to the Operating Mode Versus Resistance table for the correct resistance for each position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 11160 Gear Sensor/Switch: Description and Operation NV243 Transfer Case Description DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 11161 Mode Sensor Channel States Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 11162 Gear Sensor/Switch: Description and Operation NV273 Transfer Case Description DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Sector Angles Verses Transfer Case Position Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 11163 Mode Sensor Channel States Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Removal Gear Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Disengage the transfer case position sensor connector from the position sensor. 3. Remove the position sensor from the transfer case. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Removal > Page 11166 Gear Sensor/Switch: Service and Repair Installation INSTALLATION 1. Inspect the O-ring seal on the transfer case position sensor. Replace the O-ring if necessary. 2. Install the transfer case position sensor into the transfer case. Torque the sensor to 27 Nm (20 ft.lbs.). 3. Engage the transfer case position sensor connector to the position sensor. 4. Lower vehicle. 5. Verify proper sensor operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front Speed Sensor: Locations Sensor-Prop Shaft Speed-Front Component ID: 420 Component : SENSOR-PROP SHAFT SPEED-FRONT Connector: Name : SENSOR-PROP SHAFT SPEED-FRONT Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR 2 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 11171 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 11172 Speed Sensor: Locations Sensor-Prop Shaft Speed-Rear Component ID: 421 Component : SENSOR-PROP SHAFT SPEED-REAR Connector: Name : SENSOR-PROP SHAFT SPEED-REAR Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 2 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 11173 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front Speed Sensor: Diagrams Sensor-Prop Shaft Speed-Front Component ID: 420 Component : SENSOR-PROP SHAFT SPEED-FRONT Connector: Name : SENSOR-PROP SHAFT SPEED-FRONT Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR 2 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 11176 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 11177 Speed Sensor: Diagrams Sensor-Prop Shaft Speed-Rear Component ID: 421 Component : SENSOR-PROP SHAFT SPEED-REAR Connector: Name : SENSOR-PROP SHAFT SPEED-REAR Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Description Circuit 1 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 2 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 21 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 11178 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Sensor-Output Shaft Speed-Front Speed Sensor: Service and Repair Sensor-Output Shaft Speed-Front Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connector from the front output shaft speed sensor (1). 3. Remove the front output shaft speed sensor from the transfer case. Installation INSTALLATION 1. Install the front output shaft speed sensor (1) into the transfer case. Tighten the speed sensor to 17 Nm (12.5 ft.lbs.). 2. Engage the wiring connector to the front output shaft speed sensor. 3. Lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Sensor-Output Shaft Speed-Front > Page 11181 Speed Sensor: Service and Repair Sensor-Output Shaft Speed-Rear Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connector from the rear output shaft speed sensor (1). 3. Remove the rear output shaft speed sensor from the transfer case. Installation INSTALLATION 1. Install the rear output shaft speed sensor (1) into the transfer case. Tighten the speed sensor to 17 Nm (12.5 ft.lbs.). 2. Engage the wiring connector to the rear output shaft speed sensor. 3. Lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation > Description ABS Light: Description and Operation Description DESCRIPTION An Antilock Brake System (ABS) indicator is standard equipment on all instrument clusters. However, the instrument cluster can be programmed to disable this indicator on vehicles that are not equipped with the ABS or Rear Wheel Anti-Lock (RWAL) brake systems, which are not available in some markets. This indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. The ABS indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Failure of Anti-lock Braking System in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ABS indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation > Description > Page 11188 ABS Light: Description and Operation Operation OPERATION The ABS indicator gives an indication to the vehicle operator when the ABS system, or a circuit or component of the system is ineffective. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Controller Area Network (CAN) data bus. The ABS indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the ABS indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the ABS indicator is illuminated for about four seconds as a bulb test. The entire bulb test is a function of the CAB. - ABS Indicator Lamp-On Message - Each time the cluster receives an electronic ABS indicator lamp-ON message from the CAB, the ABS indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the CAB for five consecutive message cycles, the ABS indicator is illuminated. The indicator remains illuminated until the cluster receives a valid message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the instrument cluster is put through the actuator test, the ABS indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. - ABS Diagnostic Test - The ABS indicator is blinked ON and OFF by lamp-ON and lamp-OFF messages from the CAB during the performance of the ABS diagnostic tests. The CAB continually monitors the ABS circuits and sensors to decide whether the system is in good operating condition. The CAB then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the CAB sends a lamp-ON message after the bulb test, it indicates that the CAB has detected a system malfunction or that the ABS system has become ineffective. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the ABS indicator fails to light due to an open or short in the cluster ABS indicator circuit, the cluster sends a message notifying the CAB of the condition, then the instrument cluster and the CAB will each store a DTC. For proper diagnosis of the antilock brake system, the CAB, the EMIC, the CAN data bus or the electronic communication related to ABS indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Component ID: 199 Component : MODULE-ANTI-LOCK BRAKES Connector: Name : MODULE-ANTI-LOCK BRAKES Color : # of pins : 46 Qualifier : (AWAL) Pin Description Circuit 1-2 FUSED B(+) A111 16DG/RD 3 CAN C BUS (+) D65 20WT/LG 4-5-6 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT 7-8-9-10 - 11 - 12 LEFT FRONT WHEEL SPEED SENSOR (+) B9 20DG/LG 13 LEFT FRONT WHEEL SPEED SENSOR (-) B8 20DG/TN 14 - 15 - 16 GROUND Z107 16BK/DG 17 - 18 CAN C BUS (-) D64 20WT/LB 19 - 20 - 21 - 22 - 23 - 24 - 25 - 26 RIGHT FRONT WHEEL SPEED SENSOR (+) B7 20DG/VT 27 RIGHT FRONT WHEEL SPEED SENSOR (-) B6 20DG/WT 28 - 29 - 30 - 31 FUSED B(+) A107 12TN/RD 32 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 33 - 34 - - Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 11192 35 - 36 - 37 - 38 - 39 - 40 - 41 REAR WHEEL SPEED SENSOR (-) B22 20DG/YL 42 REAR WHEEL SPEED SENSOR (+) B222 20DG/WT 43 - 44 - 45 GROUND Z127 12BK/DG 46 - Component Location - 32 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 11193 Connector: Name : MODULE-ANTI-LOCK BRAKES Color : BLACK # of pins : 14 Qualifier : (RWAL) Pin Description Circuit 1 REAR WHEEL SPEED SENSOR (+) B222 18DG/WT 2 CAN C BUS (+) D65 18WT/LG 3 CAN C BUS (-) D64 18WT/LB 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 11194 5 LEFT FRONT WHEEL SPEED SENSOR (+) B9 18DG/LG 6 GROUND Z107 16BK/DG 7 FUSED B(+) A111 16DG/RD 8 REAR WHEEL SPEED SENSOR (-) B22 18DG/YL 9 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 10 LEFT FRONT WHEEL SPEED SENSOR (-) B8 18DG/TN 11 - 12 - 13 - 14 - Component Location - 32 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 11195 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 11196 Electronic Brake Control Module: Diagrams Component ID: 199 Component : MODULE-ANTI-LOCK BRAKES Connector: Name : MODULE-ANTI-LOCK BRAKES Color : # of pins : 46 Qualifier : (AWAL) Pin Description Circuit 1-2 FUSED B(+) A111 16DG/RD 3 CAN C BUS (+) D65 20WT/LG 4-5-6 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT 7-8-9-10 - 11 - 12 LEFT FRONT WHEEL SPEED SENSOR (+) B9 20DG/LG 13 LEFT FRONT WHEEL SPEED SENSOR (-) B8 20DG/TN 14 - 15 - 16 GROUND Z107 16BK/DG 17 - 18 CAN C BUS (-) D64 20WT/LB 19 - 20 - 21 - 22 - 23 - 24 - 25 - 26 RIGHT FRONT WHEEL SPEED SENSOR (+) B7 20DG/VT 27 RIGHT FRONT WHEEL SPEED SENSOR (-) B6 20DG/WT 28 - 29 - 30 - 31 FUSED B(+) A107 12TN/RD 32 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 33 - 34 - - Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 11197 35 - 36 - 37 - 38 - 39 - 40 - 41 REAR WHEEL SPEED SENSOR (-) B22 20DG/YL 42 REAR WHEEL SPEED SENSOR (+) B222 20DG/WT 43 - 44 - 45 GROUND Z127 12BK/DG 46 - Component Location - 32 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 11198 Connector: Name : MODULE-ANTI-LOCK BRAKES Color : BLACK # of pins : 14 Qualifier : (RWAL) Pin Description Circuit 1 REAR WHEEL SPEED SENSOR (+) B222 18DG/WT 2 CAN C BUS (+) D65 18WT/LG 3 CAN C BUS (-) D64 18WT/LB 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 11199 5 LEFT FRONT WHEEL SPEED SENSOR (+) B9 18DG/LG 6 GROUND Z107 16BK/DG 7 FUSED B(+) A111 16DG/RD 8 REAR WHEEL SPEED SENSOR (-) B22 18DG/YL 9 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 10 LEFT FRONT WHEEL SPEED SENSOR (-) B8 18DG/TN 11 - 12 - 13 - 14 - Component Location - 32 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 11200 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > Description Electronic Brake Control Module: Description and Operation Description DESCRIPTION The Antilock Brake Module (ABM) (2) is mounted to the Hydraulic Control Unit (HCU) (3) and operates the ABS system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > Description > Page 11203 Electronic Brake Control Module: Description and Operation Operation OPERATION The ABM voltage source is through the ignition switch in the RUN position. The ABM contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in a diagnostic program memory and are accessible with the scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. NOTE: If the ABM is being replaced with a new ABM is must be reprogrammed with the use of a scan tool. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Removal Electronic Brake Control Module: Service and Repair Removal REMOVAL 1. Remove the negative battery cable from the battery. 2. Pull up on the ABM harness connector release and remove connector. 3. Remove the ABM mounting bolts . 4. Remove the pump connector from the ABM. 5. Remove the ABM from the HCU . Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Removal > Page 11206 Electronic Brake Control Module: Service and Repair Installation INSTALLATION NOTE: If the ABM is being replaced with a new ABM is must be reprogrammed with the use of a scan tool. 1. Install ABM to the HCU. 2. Install the pump connector to the ABM. 3. Install mounting bolts. Tighten to 2 Nm (16 in. lbs.). 4. Install the wiring harness connector to the ABM and push down on the release to secure the connector. 5. Install negative battery cable to the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > HCU (Hydraulic Control Unit) Hydraulic Control Assembly - Antilock Brakes: Description and Operation HCU (Hydraulic Control Unit) Description DESCRIPTION The HCU (3) consists of a valve body, pump motor, low pressure accumulators, inlet valves, outlet valves and noise attenuators. Operation OPERATION Accumulators in the valve body store extra fluid released to the system for ABS mode operation. The pump provides the fluid volume needed and is operated by a DC type motor. The motor is controlled by the ABM. The valves modulate brake pressure during antilock braking and are controlled by the ABM. The HCU provides three channel pressure control to the front and rear brakes. One channel controls the rear wheel brakes in tandem. The two remaining channels control the front wheel brakes individually. During antilock braking, the solenoid valves are opened and closed as needed. During normal braking, the HCU solenoid valves and pump are not activated. The master cylinder and power booster operate the same as a vehicle without an ABS brake system. NOTE: The three modes mentioned below do occur but not necessarily in the order listed every time. During antilock braking, solenoid valve pressure modulation occurs in three stages, pressure increase, pressure hold, and pressure decrease. The valves are all contained in the valve body portion of the HCU. PRESSURE DECREASE The outlet valve is opened and the inlet valve is closed during the pressure decrease cycle. A pressure decrease cycle is initiated when speed sensor signals indicate high wheel slip at one or more wheels. At this point, the ABM closes the inlet then opens the outlet valve, which also opens the return circuit to the accumulators. Fluid pressure is allowed to bleed off (decrease) as needed to prevent wheel lock. Once the period of high wheel slip has ended, the ABM closes the outlet valve and begins a pressure increase or hold cycle as needed. PRESSURE HOLD Both solenoid valves are closed in the pressure hold cycle but only the inlet valve is energized. Fluid apply pressure in the control channel is maintained at a constant rate. The ABM maintains the hold cycle until sensor inputs indicate a pressure change is necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > HCU (Hydraulic Control Unit) > Page 11211 PRESSURE INCREASE The inlet valve is open and the outlet valve is closed during the pressure increase cycle. The pressure increase cycle is used to reapply thew brakes. This cycle controls re-application of fluid apply pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > HCU (Hydraulic Control Unit) > Page 11212 Hydraulic Control Assembly - Antilock Brakes: Description and Operation RWAL Valve Description DESCRIPTION Rear Wheel Antilock (RWAL) brake system is standard equipment on 1500 series vehicles. The RWAL brake system is designed to prevent rear wheel lock-up on virtually all types of road surfaces. RWAL braking is desirable because a vehicle which is stopped without locking the rear wheels will retain directional stability. This allows the driver to retain greater control of the vehicle during braking. The valve is located on the drivers side inner fender under the hood. The valve modulates hydraulic pressure to the rear brakes. The RWAL components include: - RWAL Valve(1) - Controller Antilock brake (CAB) - Rear Wheel Speed Sensor (WSS) Operation OPERATION When the brakes are applied, hydraulic fluid is routed from the master cylinder's secondary circuit to the RWAL valve. From there hydraulic fluid is routed to the rear brakes. The Controller Antilock Brake (CAB) contains an Electronic Variable Brake Proportioning (EVBP) control algorithm, which proportions the applied braking force to the rear wheels during braking. The EVBP function of the RWAL system takes the place of a conventional hydraulic proportioning valve. The CAB monitors the rear wheel speed through the rear wheel speed sensor and calculates an estimated vehicle deceleration. When an established deceleration threshold is exceeded, an isolation valve is closed to hold the applied brake pressure to the rear brakes constant. Upon further increases in the estimated vehicle deceleration, the isolation valve is selectively opened to increase rear brake pressure in proportion to the front brake pressure. If impending rear wheel lock-up is sensed, the CAB signals the RWAL valve to modulate hydraulic brake pressure to the rear wheels to prevent lock-up. NORMAL BRAKING Since the RWAL valve also performs the EVBP or proportioning function, vehicle deceleration under normal braking may be sufficient to trigger the EVBP function of the RWAL system without full RWAL activity as would normally occur during an impending rear wheel lock-up. As previously mentioned, the isolation valve is selectively closed and opened to increase rear brake pressure in proportion to the front brake pressure under EVBP control. Slight brake pedal pulsations may be noticed as the isolation valve is opened. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > HCU (Hydraulic Control Unit) Hydraulic Control Assembly - Antilock Brakes: Service and Repair HCU (Hydraulic Control Unit) Removal REMOVAL 1. Disconnect the battery cables from the battery. 2. Remove the battery. 3. Disconnect the electrical harness connectors. 4. Remove the brake lines from the HCU (3). 5. Remove HCU/ABM mounting bolts (1) and remove the HCU/ABM (3) from the battery tray (4). Installation INSTALLATION NOTE: If the ABM (2) is being replaced with a new ABM is must be reprogrammed with the use of a scan tool. 1. Install HCU/ABM (3) on the mounts to the battery tray (4) and Tighten the bolts to 15 Nm (11 ft. lbs.). 2. Install the brake lines to the HCU (3) and tighten to 19 Nm (170 in. lbs.). 3. Install the electrical harness connectors to the HCU/ABM (3) and push down on the release to secure the connectors. 4. Install the battery. 5. Install the battery cables to the battery. 6. Bleed ABS brake system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > HCU (Hydraulic Control Unit) > Page 11215 Hydraulic Control Assembly - Antilock Brakes: Service and Repair RWAL Valve Removal REMOVAL 1. Disconnect the battery cables from the battery. 2. Remove the battery. 3. Disconnect the electrical harness connector. 4. Remove the brake lines from the rwal valve (1). 5. Remove rwal valve mounting nuts (2) and remove the rwal valve (1). Installation INSTALLATION 1. Install rwal valve (1) and Tighten the nuts (2) to 15 Nm (11 ft. lbs.). 2. Install the brake lines to the rwal valve and tighten to 19 Nm (170 in. lbs.). 3. Install the electrical harness connector to the rwal valve and secure the connector. 4. Install the battery. 5. Install the battery cables to the battery. 6. Bleed ABS brake system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Locations Lateral Accelerometer: Locations Component ID: 393 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : # of pins : 6 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/GY 3 DYNAMICS SENSOR LOW DATA LINK D464 20WT/OR 4-5-6 GROUND Z608 20BK/LG Component Location - 52 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Locations > Page 11219 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Locations > Page 11220 Lateral Accelerometer: Diagrams Component ID: 393 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : # of pins : 6 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/GY 3 DYNAMICS SENSOR LOW DATA LINK D464 20WT/OR 4-5-6 GROUND Z608 20BK/LG Component Location - 52 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Locations > Page 11221 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Locations > Page 11222 Lateral Accelerometer: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor. The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Service and Repair > Removal Lateral Accelerometer: Service and Repair Removal REMOVAL 1. Remove the center bezel lower trim panel. 2. Remove the cup holder. 3. Disconnect the electrical connector (3) for the dynamics sensor (2). 4. Remove the 3 mounting nuts (1) for the sensor (2). 5. Remove the sensor (2) from the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Service and Repair > Removal > Page 11225 Lateral Accelerometer: Service and Repair Installation INSTALLATION 1. Install the dynamics sensor on the mounting studs (2). 2. Install the mounting nuts (1) Tighten to 24 Nm (200 in. lbs.). 3. Reconnect the electrical connector (3). 4. Install the cup holder. 5. Install the center bezel lower trim panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set Steering Angle Sensor: Customer Interest ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set NUMBER: 08-044-06 GROUP: Electrical DATE: October 07, 2006 SUBJECT: DTC C1240 - Steering Angle Sensor Over Travel Performance OVERVIEW: This bulletin involves the diagnosis and possible replacement of the Steering Angle Sensor. MODELS: 2007 (DR) Ram Truck NOTE: This bulletin applies to vehicle equipped with the Electronic Stability Program (sales code BNB) and built prior to October 03, 2006 (MDH 1003XX). SYMPTOM/CONDITION: The customer may experience an illumination on the instrument cluster of the "ABS" (Anti-Lock Brake System) and/or the "ESP / BAS" (Electronic Stability Program / Brake Assist System) Warning Lights. Investigation may reveal the presence of Diagnostic Trouble Code (DTC) C1240 Steering Angle Sensor Over Travel Performance (SAS). DIAGNOSIS: 1. Perform the diagnostic test procedure for DTC C1240. This diagnostic procedure can be found on TechCONNECT: select the SERVICE INFO tab > 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 340/445E5P AWAL > DIAGNOSIS and TESTING > C1240 - Steering Angle Sensor Over Travel Performance (SAS). 2. If the diagnostic test procedure for DTC C1240 determines that the Steering Angle Sensor is at fault, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Before starting this procedure, be certain that the front wheels are in the straight-ahead position. 1. Replace the steering column clockspring. Refer to TechCONNECT for detailed service procedures: select the SERVICE INFO tab > 8 - ELECTRICAL > RESTRAINTS > CLOCKSPRING > REMOVAL and INSTALLATION. 2. Clear offsets by initializing the ABS ECU using StarSCAN. 3. Perform the ABS VERIFICATION TEST. This test can be found in: 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 3401445E5P AWAL > STANDARD PROCEDURE > ABS VERIFICATION TEST. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set > Page 11234 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set Steering Angle Sensor: All Technical Service Bulletins ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set NUMBER: 08-044-06 GROUP: Electrical DATE: October 07, 2006 SUBJECT: DTC C1240 - Steering Angle Sensor Over Travel Performance OVERVIEW: This bulletin involves the diagnosis and possible replacement of the Steering Angle Sensor. MODELS: 2007 (DR) Ram Truck NOTE: This bulletin applies to vehicle equipped with the Electronic Stability Program (sales code BNB) and built prior to October 03, 2006 (MDH 1003XX). SYMPTOM/CONDITION: The customer may experience an illumination on the instrument cluster of the "ABS" (Anti-Lock Brake System) and/or the "ESP / BAS" (Electronic Stability Program / Brake Assist System) Warning Lights. Investigation may reveal the presence of Diagnostic Trouble Code (DTC) C1240 Steering Angle Sensor Over Travel Performance (SAS). DIAGNOSIS: 1. Perform the diagnostic test procedure for DTC C1240. This diagnostic procedure can be found on TechCONNECT: select the SERVICE INFO tab > 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 340/445E5P AWAL > DIAGNOSIS and TESTING > C1240 - Steering Angle Sensor Over Travel Performance (SAS). 2. If the diagnostic test procedure for DTC C1240 determines that the Steering Angle Sensor is at fault, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Before starting this procedure, be certain that the front wheels are in the straight-ahead position. 1. Replace the steering column clockspring. Refer to TechCONNECT for detailed service procedures: select the SERVICE INFO tab > 8 - ELECTRICAL > RESTRAINTS > CLOCKSPRING > REMOVAL and INSTALLATION. 2. Clear offsets by initializing the ABS ECU using StarSCAN. 3. Perform the ABS VERIFICATION TEST. This test can be found in: 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 3401445E5P AWAL > STANDARD PROCEDURE > ABS VERIFICATION TEST. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set > Page 11240 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Page 11241 Steering Angle Sensor: Locations Component ID: 425 Component : SENSOR-STEERING ANGLE Connector: Name : SENSOR-STEERING ANGLE Color : BLACK # of pins : 4 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/LG 2 GROUND Z455 20BK/PK 3 CAN C BUS (-) D64 20WT/LB 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Page 11242 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Page 11243 Steering Angle Sensor: Diagrams Component ID: 425 Component : SENSOR-STEERING ANGLE Connector: Name : SENSOR-STEERING ANGLE Color : BLACK # of pins : 4 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/LG 2 GROUND Z455 20BK/PK 3 CAN C BUS (-) D64 20WT/LB 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Page 11244 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Description and Operation > Electronic Stability Program/Brake Assist System Indicator Traction Control Indicator Lamp: Description and Operation Electronic Stability Program/Brake Assist System Indicator Description DESCRIPTION An Electronic Stability Program/Brake Assist System (ESP/BAS) indicator is only found in the instrument clusters for vehicles equipped with a gasoline engine. However, on vehicles not equipped with the optional ESP/BAS, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The ESP/BAS indicator consists of a stencil-like cutout of the text ESP BAS in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ESP/BAS indicator is serviced as a unit with the instrument cluster. Operation OPERATION The ESP/BAS indicator gives an indication to the vehicle operator when a problem has been detected in the Electronic Stability Program (ESP)/Brake Assist System (BAS). This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) and the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The ESP/BAS indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the ESP/BAS indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the ESP/BAS indicator is illuminated for about four seconds as a bulb test. - ESP/BAS Indicator Lamp-On Message - Each time the cluster receives an electronic ESP/BAS indicator lamp-ON message from the CAB or the TIPM, the ESP/BAS indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the CAB or TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the ESP/BAS indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The CAB and TIPM continually monitor the ESP/BAS system circuits and sensors to decide whether the system is in good operating condition and the proper outputs to the components of the system. The CAB or TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For proper diagnosis of the ESP/BAS system, the CAB, the TIPM, the EMIC, the CAN data bus or the electronic communication related to ESP/BAS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Description and Operation > Electronic Stability Program/Brake Assist System Indicator > Page 11249 indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Description and Operation > Electronic Stability Program/Brake Assist System Indicator > Page 11250 Traction Control Indicator Lamp: Description and Operation Traction Control Indicator Description DESCRIPTION An Electronic Stability Program/Brake Assist System (ESP/BAS)/Traction Control System (TCS) traction control indicator is only found in the instrument clusters for vehicles equipped with a gasoline engine. However, on vehicles not equipped with the optional ESP/BAS/TCS, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The traction control indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Stability - Anti-Spin in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The traction control indicator is serviced as a unit with the instrument cluster. Operation OPERATION The traction control indicator gives an indication to the vehicle operator when the Electronic Stability Program (ESP)/Brake Assist System (BAS)/Traction Control System (TCS) has been activated. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Controller Area Network (CAN) data bus. The traction control indicator is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be OFF when the ignition switch is in any position except ON or START. The indicator only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the traction control indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the traction control indicator is illuminated for about four seconds as a bulb test. The entire bulb test is a function of the CAB. - Traction Control Indicator Lamp-On Message - Each time the cluster receives an electronic traction control indicator lamp-ON message from the CAB indicating that the ESP/BAS/TCS has been activated, the traction control indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the traction control indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The CAB continually monitors the status of the inputs to the ESP/BAS/TCS systems to determine the proper outputs to the components of the Antilock Brake System (ABS). The CAB then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the traction control indicator or the instrument cluster circuitry that controls the indicator, refer to Instrument Cluster/Carrier Testing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Description and Operation > Electronic Stability Program/Brake Assist System Indicator > Page 11251 For proper diagnosis of the ESP/BAS/TCS, the CAB, the EMIC, the CAN data bus or the electronic communication related to traction control indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations Traction Control Switch: Locations Component ID: 463 Component : SWITCH-ESP Connector: Name : SWITCH-ESP Color : # of pins : 6 Pin Description Circuit 1 GROUND Z936 20BK/DG 2 PANEL LAMPS DRIVER E11 20OR/DB 3 ESP ON/OFF SENSE B46 20DG/WT 4 SENSOR GROUND G94 20VT/DB 5-6-Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 11255 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 11256 Traction Control Switch: Diagrams Component ID: 463 Component : SWITCH-ESP Connector: Name : SWITCH-ESP Color : # of pins : 6 Pin Description Circuit 1 GROUND Z936 20BK/DG 2 PANEL LAMPS DRIVER E11 20OR/DB 3 ESP ON/OFF SENSE B46 20DG/WT 4 SENSOR GROUND G94 20VT/DB 5-6-Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 11257 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 11258 Traction Control Switch: Description and Operation DESCRIPTION The ESP switch is located just below the heater and air conditioner controls in the center stack area of the instrument panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Service and Repair > Removal Traction Control Switch: Service and Repair Removal REMOVAL 1. Remove the radio trim panel (1). 2. Disconnect the electrical connectors from the radio trim panel. 3. Remove the ESP switch (1) from the switch bank (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Service and Repair > Removal > Page 11261 Traction Control Switch: Service and Repair Installation INSTALLATION 1. Install the new switch (1) in the switch bank (2). 2. Reconnect the electrical connectors for the radio trim panel. 3. Install the radio trim panel (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Left Front Component ID: 434 Component : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Color : # of pins : 2 Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR (+) B9 20DG/LG Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR (+) B9 18DG/LG 2 LEFT FRONT WHEEL SPEED SENSOR (-) B8 20DG/TN 2 LEFT FRONT WHEEL SPEED SENSOR (-) B8 18DG/TN Component Location - 38 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 11266 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 11267 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Rear Component ID: 436 Component : SENSOR-WHEEL SPEED-ABS-REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-REAR Color : BLACK # of pins : 2 Qualifier : (EXCEPT ESP) Pin Description Circuit 1 REAR WHEEL SPEED SENSOR (-) B22 18DG/YL 2 REAR WHEEL SPEED SENSOR (+) B222 18DG/WT Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 11268 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 11269 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Left Rear Component ID: 435 Component : SENSOR-WHEEL SPEED-ABS-LEFT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT REAR Color : # of pins : 2 Qualifier : (ESP) Pin Description Circuit 1 REAR WHEEL SPEED SENSOR (-) B3 18DG/YL 2 REAR WHEEL SPEED SENSOR (+) B4 18DG/GY Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 11270 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 11271 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Right Front Component ID: 437 Component : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Color : # of pins : 2 Pin Description Circuit 1 RIGHT FRONT WHEEL SPEED SENSOR (+) B7 20DG/VT 2 RIGHT FRONT WHEEL SPEED SENSOR (-) B6 20DG/WT Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 11272 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 11273 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Right Rear Component ID: 438 Component : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Color : # of pins : 2 Qualifier : (ESP) Pin Description Circuit 1 RIGHT REAR WHEEL SPEED SENSOR (-) B1 18DG/OR 2 RIGHT REAR WHEEL SPEED SENSOR (+) B2 18DG/LB Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 11274 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Left Front Component ID: 434 Component : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Color : # of pins : 2 Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR (+) B9 20DG/LG Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR (+) B9 18DG/LG 2 LEFT FRONT WHEEL SPEED SENSOR (-) B8 20DG/TN 2 LEFT FRONT WHEEL SPEED SENSOR (-) B8 18DG/TN Component Location - 38 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 11277 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 11278 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Rear Component ID: 436 Component : SENSOR-WHEEL SPEED-ABS-REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-REAR Color : BLACK # of pins : 2 Qualifier : (EXCEPT ESP) Pin Description Circuit 1 REAR WHEEL SPEED SENSOR (-) B22 18DG/YL 2 REAR WHEEL SPEED SENSOR (+) B222 18DG/WT Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 11279 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 11280 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Left Rear Component ID: 435 Component : SENSOR-WHEEL SPEED-ABS-LEFT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT REAR Color : # of pins : 2 Qualifier : (ESP) Pin Description Circuit 1 REAR WHEEL SPEED SENSOR (-) B3 18DG/YL 2 REAR WHEEL SPEED SENSOR (+) B4 18DG/GY Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 11281 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 11282 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Right Front Component ID: 437 Component : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Color : # of pins : 2 Pin Description Circuit 1 RIGHT FRONT WHEEL SPEED SENSOR (+) B7 20DG/VT 2 RIGHT FRONT WHEEL SPEED SENSOR (-) B6 20DG/WT Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 11283 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 11284 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Right Rear Component ID: 438 Component : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Color : # of pins : 2 Qualifier : (ESP) Pin Description Circuit 1 RIGHT REAR WHEEL SPEED SENSOR (-) B1 18DG/OR 2 RIGHT REAR WHEEL SPEED SENSOR (+) B2 18DG/LB Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 11285 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Description Wheel Speed Sensor: Description and Operation Description DESCRIPTION The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front hub/bearings. The third sensor is mounted on top of the rear axle differential housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Description > Page 11288 Wheel Speed Sensor: Description and Operation Operation OPERATION The Wheel Speed Sensor consists of a magnet (1) surrounded by windings from a single strand of wire (5). The sensor sends a small AC signal to the ABM. This signal is generated by magnetic induction. The magnetic induction is created when a toothed sensor ring (exciter ring or tone wheel) (4) passes the stationary magnetic WSS. When the ring gear is rotated, the exciter ring (4) passes the tip of the WSS. As the exciter ring tooth approaches the tip of the WSS, the magnetic lines of force expand, causing the magnetic field to cut across the sensor's windings (5). This, in turn causes current to flow through the WSS circuit in one direction. When the exciter ring tooth moves away from the sensor tip, the magnetic lines of force collapse cutting the winding in the opposite direction. This causes the current to flow in the opposite direction. Every time a tooth of the exciter ring passes the tip of the WSS, an AC signal is generated current. Each AC signal (positive to negative signal or squarewave) is interpreted by the ABM. It then compares the frequency of the sinewave to a time value to calculate vehicle speed. The ABM continues to monitor the frequency to determine a deceleration rate that would indicate a possible wheel-locking tendency. The signal strength of any magnetic induction sensor is directly affected by: - Magnetic field strength; the stronger the magnetic field, the stronger the signal - Number of windings in the sensor; more windings provide a stronger signal - Exciter ring speed; the faster the exciter ring/tone wheel rotates, the stronger the signal will be - Distance (3) "air gap" between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring/tone wheel, the stronger the signal will be. The WSS is not adjustable. A clearance specification has been established for manufacturing tolerances. If the clearance is not within these specifications, then either the WSS or other components may be damaged. The clearance between the WSS and the exciter ring is 0.005 0.050 in. The assembly plant performs a "Rolls Test" on every vehicle that leaves the assembly plant. One of the test performed is a test of the WSS. To properly test the sensor, the assembly plant connects test equipment to the Data Link Connector (DLC). This connector is located to the right of the steering column and attached to the lower portion of the instrument panel. The rolls test terminal is spliced to the WSS circuit. The vehicle is then driven on a set of rollers and the WSS output is monitored for proper operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Page 11289 Wheel Speed Sensor: Testing and Inspection REAR WHEEL ANTILOCK Diagnosis of base brake conditions which are mechanical in nature should be performed first. This includes brake noise, lack of power assist, parking brake, or vehicle vibration during normal braking. The RWAL brake system performs several self-tests every time the ignition switch is turned on and the vehicle is driven. The CAB monitors the system inputs and outputs circuits to verify the system is operating properly. If the CAB senses a malfunction in the system it will set a DTC into memory and trigger the warning lamp. NOTE: A scan tool is used to diagnose the RWAL system. For test procedures refer to the ABS Electrical Diagnostic. See: Testing and Inspection Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Sensor- Wheel Speed-ABS-Front Wheel Speed Sensor: Service and Repair Sensor- Wheel Speed-ABS-Front Removal REMOVAL 1. Remove the front rotor. 2. Remove the wheel speed sensor mounting bolt (1) from the hub (3). 3. Remove the wheel speed sensor (2) from the hub (3). 4. Remove the wiring from the clips and disconnect the electrical connector. Installation INSTALLATION 1. Install the wiring to the clips and Reconnect the electrical connector. 2. Install the wheel speed sensor (2) to the hub (3). 3. Install the wheel speed sensor mounting bolt (1) to the hub (3). Tighten the bolt to 21 Nm (190 in. lbs.). 4. Install the front rotor and brake caliper assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Sensor- Wheel Speed-ABS-Front > Page 11292 Wheel Speed Sensor: Service and Repair Sensor-Wheel Speed-ABS-Rear Removal REMOVAL 1. Raise the vehicle on a hoist. 2. Remove the brake line mounting nut and remove the brake line from the sensor stud. 3. Remove the mounting stud (2) from the sensor and shield. 4. Remove the sensor (1) and shield from the differential housing (3). 5. Disconnect the sensor wire harness and remove the sensor (1). Installation INSTALLATION 1. Connect the harness to the sensor. Be sure the seal is securely in place between the sensor and the wiring connector. 2. Install the O-ring on the sensor (if removed). 3. Insert the sensor (1) in the differential housing (3). 4. Install the sensor shield. 5. Install the sensor mounting stud (2) and tighten to 24 Nm (200 in. lbs.). 6. Install the brake line on the sensor stud (2)and install the nut. 7. Lower the vehicle. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Sensor- Wheel Speed-ABS-Front > Page 11293 1. Raise the vehicle on a hoist. 2. Disconnect the wheel speed sensor electrical connector (3). 3. Remove the mounting bolt (1) from the sensor (4). 4. Remove the sensor (4) from the brake caliper adapter (2). Installation INSTALLATION 1. Insert the wheel speed sensor (4) in the brake caliper adapter (2). 2. Install the sensor mounting bolt (1) and tighten to 24 Nm (200 in. lbs.). 3. Reconnect the electrical wiring connector (3) to the sensor (4). 4. Lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations Yaw Rate Sensor: Locations Component ID: 393 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : # of pins : 6 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/GY 3 DYNAMICS SENSOR LOW DATA LINK D464 20WT/OR 4-5-6 GROUND Z608 20BK/LG Component Location - 52 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations > Page 11297 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations > Page 11298 Yaw Rate Sensor: Diagrams Component ID: 393 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : # of pins : 6 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/GY 3 DYNAMICS SENSOR LOW DATA LINK D464 20WT/OR 4-5-6 GROUND Z608 20BK/LG Component Location - 52 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations > Page 11299 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations > Page 11300 Yaw Rate Sensor: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor. The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Service and Repair > Removal Yaw Rate Sensor: Service and Repair Removal REMOVAL 1. Remove the center bezel lower trim panel. 2. Remove the cup holder. 3. Disconnect the electrical connector (3) for the dynamics sensor (2). 4. Remove the 3 mounting nuts (1) for the sensor (2). 5. Remove the sensor (2) from the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Service and Repair > Removal > Page 11303 Yaw Rate Sensor: Service and Repair Installation INSTALLATION 1. Install the dynamics sensor on the mounting studs (2). 2. Install the mounting nuts (1) Tighten to 24 Nm (200 in. lbs.). 3. Reconnect the electrical connector (3). 4. Install the cup holder. 5. Install the center bezel lower trim panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Manual Bleeding Brake Bleeding: Service and Repair Manual Bleeding MANUAL BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. 1. Remove reservoir filler caps and fill reservoir. 2. If calipers were overhauled, open all caliper bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. 3. Attach one end of bleed hose (1) to bleed screw and insert opposite end in glass container (2) partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. NOTE: Bleed procedure should be in this order (1) Right rear (2) Left rear (3) Right front (4) Left front. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. 5. Before moving the vehicle verify the pedal is firm and not mushy. 6. Top off the brake fluid and install the reservoir cap. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 11308 Brake Bleeding: Service and Repair Pressure Bleeding PRESSURE BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15-20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 11309 Brake Bleeding: Service and Repair Master Cylinder MASTER CYLINDER BLEEDING A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. 1. Mount master cylinder in vise. 2. Attach bleed tubes to cylinder outlet ports (1). Then position each tube end into reservoir (2). 3. Fill reservoir with fresh brake fluid. 4. Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 11310 Brake Bleeding: Service and Repair ABS Brake Bleeding ABS BRAKE BLEEDING ABS system bleeding requires conventional bleeding methods plus use of a scan tool. The procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the HCU pump and solenoids. A second base brake bleeding procedure is then required to remove any air remaining in the system. 1. Perform base brake bleeding. 2. Connect scan tool to the Data Link Connector. 3. Select ANTILOCK BRAKES, followed by MISCELLANEOUS, then ABS BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 11311 Brake Bleeding: Service and Repair Booster-Hydro-Boost Brake BLEEDING The hydraulic booster is generally self-bleeding, this procedure will normally bleed the air from the booster. Normal driving and operation of the unit will remove any remaining trapped air. 1. Fill power steering pump reservoir. 2. Disconnect fuel shutdown relay and crank the engine for several seconds, Refer to Fuel System for relay location and WARNING. 3. Check fluid level and add if necessary. 4. Connect fuel shutdown relay and start the engine. 5. Turn the steering wheel slowly from lock to lock twice. 6. Stop the engine and discharge the accumulator by depressing the brake pedal 5 times. 7. Start the engine and turn the steering wheel slowly from lock to lock twice. 8. Turn off the engine and check fluid level and add if necessary. NOTE: If fluid foaming occurs, wait for foam to dissipate and repeat steps 7 and 8. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Description and Operation > Adjustable Pedals System Brake Pedal Assy: Description and Operation Adjustable Pedals System DESCRIPTION The Adjustable Pedals System (APS) is designed to enable the fore and aft repositioning of the brake and accelerator pedals. This results in improved ergonomics in relation to the steering wheel for taller and shorter drivers. Being able to adjust the pedal positions also allows the driver to set steering wheel tilt and seat position to the most comfortable position. The position of the brake and accelerator pedals can be adjusted without compromising safety or comfort in actuating the pedals. Change of pedal position is accomplished by means of a motor driven screw. Operating the adjustable pedal switch activates the pedal drive motor (1). The pedal drive motor turns a screw that changes the position of the brake and accelerator pedals. The pedal can be moved rearward (closer to the driver) or forward (away from driver). The brake pedal is moved on its drive screw to a position where the driver feels most comfortable. The accelerator pedal is moved at the same time and the same distance as the brake pedal. Neither the pedal drive motor (1) nor drive mechanism are subject to the mechanical stress of brake or accelerator application. - SYSTEM FEATURES: - Range of Adjustment: The pedals may be adjusted up to 3 in. (75 mm) - Pedal Adjustment Speed: 0.5 in./sec (12.5 mm/sec) - Pedal Adjustment Inhibitors: Pedal adjustment is inhibited when the vehicle is in reverse or when cruise control is activated. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Description and Operation > Adjustable Pedals System > Page 11316 Brake Pedal Assy: Description and Operation Pedal Description DESCRIPTION NOTE: The brake pedal is serviced as a complete assembly including accelerator pedal and the bracket. A suspended-type brake pedal is used. The pedal is attached to the pedal support bracket with a pivot shaft pin (3) and bushings (2). If the bushings (2) become dry a spray lubricant can be used to eliminate noises. The booster push rod is attached to the pedal with a clip (1). The pedal (4), bushings (2), pivot pin (3) and support bracket are not serviceable components. Operation OPERATION The brake pedal is attached to the booster push rod. When the pedal is depressed, the primary booster push rod is depressed which moves the booster secondary rod. The booster secondary rod depress the master cylinder piston. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Removal Brake Pedal Assy: Service and Repair Removal REMOVAL NOTE: The brake pedal is serviced as a complete assembly including accelerator pedal and the bracket. 1. Disconnect the negative battery cable. 2. Remove the steering column opening cover. 3. Remove the brake lamp switch and discard. 4. On vehicles equipped with adjustable pedals. Disconnect the adjuster cable (1) to the pedal (2). 5. Remove the steering column. 6. Remove the brake booster (5). 7. Disconnect the electrical connectors. 8. Remove the module mounting bolts. 9. Disconnect the accelerator pedal cable. 10. Remove the pedal assembly mounting nuts/fasteners (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Removal > Page 11319 Brake Pedal Assy: Service and Repair Installation INSTALLATION 1. Install the pedal assembly (4) to the vehicle. 2. Install the mounting bolts (3) and tighten to 28 Nm (21 ft. lbs.). 3. Reconnect the accelerator cable (1) to the pedal (2). 4. Install the module mounting bolts and tighten to 38 Nm (28 ft. lbs.). 5. Reconnect the electrical connectors. 6. Install the brake booster. 7. Install the steering column. 8. Install a new brake lamp switch. 9. On vehicles equipped with adjustable brake pedal.Reconnect the electrical connector to the motor and the adjuster cable at the pedal. 10. Install the steering column opening cover. 11. Reconnect the negative battery cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > Description Brake Warning Indicator: Description and Operation Description DESCRIPTION A brake indicator is standard equipment on all instrument clusters. This indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. The brake indicator consists of a stencil-like cutout of the word BRAKE and the International Control and Display Symbol icon for Brake Failure in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The brake indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > Description > Page 11324 Brake Warning Indicator: Description and Operation Operation OPERATION The brake indicator gives an indication to the vehicle operator when the parking brake is applied, when there are certain brake hydraulic system malfunctions as indicated by a low brake hydraulic fluid level condition, or when the brake fluid level switch is disconnected. The brake indicator can also give an indication when certain faults are detected in the Antilock Brake System (ABS). This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming, electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Controller Area Network (CAN) data bus, and a hard wired input from the park brake switch. The brake indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the brake indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the brake indicator is illuminated for about four seconds as a bulb test. The entire bulb test is a function of the CAB. - Brake Indicator Lamp-On Message - Each time the cluster receives an electronic brake indicator lamp-ON message from the CAB, the brake indicator will be illuminated. The CAB may also send lamp-ON messages as feedback during ABS diagnostic procedures. The indicator remains illuminated until the cluster receives a lamp-OFF message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Park Brake Switch Input - Each time the cluster detects ground on the park brake switch sense circuit (park brake switch closed = park brake applied or not fully released) while the ignition switch is in the ON position, the brake indicator flashes ON and OFF. The indicator continues to flash until the park brake switch sense input to the cluster is an open circuit (park brake switch open = park brake fully released), or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the instrument cluster is put through the actuator test, the brake indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The park brake switch on the park brake pedal mechanism provides a hard wired ground input to the instrument cluster circuitry through the park brake switch sense circuit whenever the park brake is applied or not fully released. The CAB continually monitors the ABS system circuits and sensors, including the brake fluid level switch on the brake master cylinder reservoir, to decide whether the system is in good operating condition. The CAB then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the CAB sends a lamp-ON message after the bulb test, it indicates that the CAB has detected a brake hydraulic system malfunction or that the ABS system has become ineffective. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. For further diagnosis of the brake indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. The hard wired park brake switch input to the instrument cluster may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. For proper diagnosis of the brake fluid level switch, the ABS, the CAB, the EMIC, the CAN data bus or the electronic communication related to brake indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > Page 11325 Brake Warning Indicator: Testing and Inspection BRAKE INDICATOR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. The hard wired park brake switch input to the EMIC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the Controller Antilock Brake (CAB), the Controller Area Network (CAN) data bus, or the electronic message inputs also used by the EMIC to provide brake indicator operation. The most reliable, efficient, and accurate means to diagnose the EMIC, the CAB, the CAN data bus or the electronic communication related to brake indicator operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Description and Operation > Description Brake Caliper: Description and Operation Description Light Duty (LD) Calipers LIGHT DUTY (LD) CALIPERS NOTE: Petroleum based grease should not be used on any of the rubber components of the caliper, Use only Non-Petroleum based grease. The calipers are a dual piston type. The calipers are free to slide laterally, this allows continuous compensation for lining wear. Heavy Duty (HD) Calipers HEAVY DUTY (HD) CALIPERS The calipers are a dual piston type in the front & rear. The calipers are free to slide laterally, this allows continuous compensation for lining wear. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Description and Operation > Description > Page 11331 Brake Caliper: Description and Operation Operation DISC BRAKE CALIPER When the brakes are applied fluid pressure is exerted against the caliper piston (2). The fluid pressure is exerted equally and in all directions. This means pressure exerted against the caliper piston and within the caliper bore will be equal. Fluid pressure applied to the piston is transmitted directly to the inboard brake pad (5). This forces the pad lining against the inner surface of the disc brake rotor. At the same time, fluid pressure within the piston bore forces the caliper to slide inward on the mounting bolts. This action brings the outboard brake pad lining (6) into contact with the outer surface of the disc brake rotor. In summary, fluid pressure acting simultaneously on both piston and caliper, produces a strong clamping action. When sufficient force is applied, friction will attempt to stop the rotors from turning and bring the vehicle to a stop. Application and release of the brake pedal generates only a very slight movement of the caliper and piston. Upon release of the pedal, the caliper and piston return to a rest position. The brake pads do not retract an appreciable distance from the rotor. In fact, clearance is usually at, or close to zero. The reasons for this are to keep road debris from getting between the rotor and lining and in wiping the rotor surface clear each revolution. The caliper piston seal (4) controls the amount of piston (2) extension needed to compensate for normal lining wear. During brake application, the seal is deflected outward by fluid pressure and piston movement (6). When the brakes (and fluid pressure) are released, the seal relaxes and retracts the piston (3). The amount of piston retraction is determined by the amount of seal deflection. Generally the amount is just enough to maintain contact between the piston and inboard brake pad. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement Brake Caliper: Removal and Replacement Front - Heavy Duty (HD) FRONT - HEAVY DUTY (HD) CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system. 2. Raise and support the vehicle. 3. Remove the tire and wheel assembly. 4. Compress the disc brake caliper. 5. Remove the banjo bolt and discard the copper washer. 6. Remove the caliper slide bolts. 7. Remove the disc brake caliper. Front - Light Duty (LD) FRONT - LIGHT DUTY (LD) CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose with result. Provide a suitable support to hang the caliper securely. 1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system. 2. Raise and support the vehicle. 3. Remove the tire and wheel assembly. 4. Compress the disc brake caliper (6). 5. Remove the banjo bolt (4) and discard the copper washers. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11334 6. Remove the caliper slide pin bolts (2). 7. Remove the disc brake caliper (1) from the caliper adapter (2). 8. Remove the caliper slide pins from the adapter. Rear REAR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11335 CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system. 2. Raise and support vehicle. 3. Remove the wheel and tire assembly. 4. Drain small amount of fluid from master cylinder brake reservoir with suction gun. 5. Remove the brake hose banjo bolt and discard the copper washers if replacing caliper. 6. Remove the caliper slide bolts (3). 7. Remove the caliper (6) from vehicle. Front - Heavy Duty (HD) FRONT - HEAVY DUTY (HD) NOTE: Install a new copper washers on the banjo bolt when installing 1. Install the disc brake caliper. CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt. 2. Install the banjo bolt with new copper washers to the caliper. Tighten to 27 Nm (20 ft. lbs.) 3. Install the caliper slide pin bolts. tighten to 32 Nm (24 ft. lbs.) 4. Remove the prop rod. 5. Bleed the area of repair for the brake system, If a proper pedal is not felt during bleeding an area of repair then a base bleed system must be performed. 6. Install the tire and wheel assembly 7. Lower the vehicle. Front - Light Duty (LD) FRONT - LIGHT DUTY (LD) NOTE: Petroleum based grease should not be used on any of the rubber components of the caliper, Use only Non-Petroleum based grease. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11336 NOTE: Clean slide pin bores thoroughly to remove any old grease. NOTE: Use grease packets included with kit or Dow Corning-807(R) grease. 1. Thoroughly coat the new slide pins (3) on all working surfaces. 2. Install the boot (2) onto the slide pin (3) and then insert into the adapter (1). 3. Push the pin (3) all the way into the adapter (1) and carefully expel the trapped air by gently pushing on the boot (2) near the slide pin head (3). NOTE: Install a new copper washers on the banjo bolt when installing 4. Install the disc brake caliper (1) to the brake caliper adapter (2). 5. Install the banjo bolt (4) with new copper washers to the caliper (6). Tighten to 28 Nm (250 in. lbs.) 6. Install the caliper slide pin bolts (2). Tighten to 32 Nm (24 ft. lbs.) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11337 7. Remove the prop rod. 8. Bleed the area of repair for the brake system, If a proper pedal is not felt during bleeding an area of repair then a base bleed system must be performed.. 9. Install the tire and wheel assembly. 10. Lower the vehicle. Rear REAR 1. Install caliper (6) to the caliper adapter (1). 2. Coat the caliper mounting slide pin bolts (3) with silicone grease. Then install and tighten the bolts to 30 Nm (22 ft. lbs.). 3. Install the brake hose banjo bolt if removed. 4. Install the brake hose (4) to the caliper (6) with new seal washers and tighten fitting bolt to 27 Nm (245 in. lbs.). CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt. 5. Remove the prop rod from the brake pedal. 6. Bleed the area of repair for the brake system, If a proper pedal is not felt during bleeding an area of repair then a base bleed system must be performed.. 7. Install the wheel and tire assemblies. 8. Remove the supports and lower the vehicle. 9. Verify a firm pedal before moving the vehicle. Front FRONT 1. Raise and support the vehicle. 2. Remove the front wheel and tire assembly. 3. Remove the caliper slide pin bolts (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11338 4. Remove the disc brake caliper (1) from the adapter (2). CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 5. Remove the inboard (4) and outboard (2) brake pads. 6. Remove the caliper adapter mounting bolts (5). 7. Remove the caliper slide pins from the adapter. Rear REAR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11339 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Drain a small amount of fluid from master cylinder brake reservoir with a clean suction gun. 4. Bottom the caliper pistons into the caliper by prying the caliper over. 5. Remove the caliper slide bolts. 6. Remove the disc brake caliper from the mount. CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 7. Remove the inboard and outboard brake pads (1). 8. Remove the anti-rattle clips (2). 9. Remove the caliper adapter mounting bolts (4). 10. Remove the caliper adapter. Front FRONT NOTE: Petroleum based grease should not be used on any of the rubber components of the caliper, Use only a Non-Petroleum based grease, such as Dow Corning-807(R) grease. NOTE: Clean slide pin bores thoroughly to remove any old grease. NOTE: Use grease packets included with kit or Dow Corning-807(R) grease. 1. Thoroughly coat the new slide pins (3) on all working surfaces. 2. Install the boot (2) onto the slide pin (3) and then insert into the adapter (1). 3. Push the pin (3) all the way into the adapter (1) and carefully expel the trapped air by gently pushing on the boot (2) near the slide pin head (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11340 4. Install the caliper adapter mounting bolts (5). Tighten the mounting bolts to 176 Nm (130 ft.lbs) LD or Tighten the mounting bolts to 339 Nm (250 ft.lbs) HD. 5. Install the inboard (4) and outboard (2) pads. 6. Install the caliper (2) and the caliper slide pin bolts (4). 7. Install the tire and wheel assembly. Rear REAR 1. Install the caliper adapter mounting bolts (4). Tighten the mounting bolts to 135 Nm (100 ft.lbs) LD or tighten to 197 Nm (145 ft.lbs.) HD. 2. Install the anti-rattle clips (2). 3. Install the inboard and outboard pads (1). 4. Install the caliper mounting bolts. 5. Install the tire and wheel assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11341 Removal REAR 1. Remove wheel and tire assembly. 2. Remove the disc brake caliper. 3. Remove the caliper adapter. 4. Remove the rotor. 5. Remove the axle shaft. 6. Remove the park brake shoes. 7. Remove the parking brake cable from the brake lever. 8. Remove the bolts (3) attaching the support plate to the axle and remove the support plate. 9. Remove the caliper adapter mount (1) from the axle housing (2). Installation INSTALLATION 1. Install the caliper adapter mount (1) on the axle housing (2). 2. Install support plate on axle flange. Tighten attaching bolts (3) to 68 Nm (50 ft. lbs.) LD or tighten to 203 Nm (150 ft.lbs.) HD. 3. Install parking brake cable in the brake lever. 4. Install the park brake shoes. 5. Install axle shaft. 6. Adjust brake shoes to drum with brake gauge. 7. Install the rotor. 8. Install the caliper adapter. 9. Install the caliper. 10. Install wheel and tire assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11342 Brake Caliper: Overhaul Light Duty (LD) LIGHT DUTY (LD) 1. Drain the brake fluid from caliper. 2. C-clamp (2) a block of wood (1) over one piston. 3. Take another piece of wood and pad it with one-inch thickness of shop towels (2). Place this piece in the outboard shoe side of the caliper in front of the other piston. This will cushion and protect caliper piston during removal. 4. To remove the caliper piston direct short bursts of low pressure air with a blow gun through the caliper brake hose port. Use only enough air pressure to ease the piston out. CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. WARNING: Never attempt to catch the piston as it leaves the bore. This could result in personal injury. 5. Remove the C-clamp and block of wood from the caliper and clamp it over the dust boot of the first piston removed. This will seal the empty piston bore. 6. Move the padded piece of wood in front of the other piston. 7. Remove the second piston using the same procedure with short bursts of low pressure air. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11343 8. Remove piston dust boots (2) by hand. CAUTION: Do not scratch piston bore while removing the seals. 9. Remove the lip seal from the groove (4) with a pick tool (3). 10. Remove piston seals (2) from caliper (1) by hand. Heavy Duty (HD) HEAVY DUTY (HD) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11344 1. Drain the brake fluid from caliper. 2. C-clamp (2) a block of wood (1) over one piston. 3. Take another piece of wood and pad it with one-inch thickness of shop towels (2). Place this piece in the outboard shoe side of the caliper in front of the other piston. This will cushion and protect caliper piston during removal. 4. To remove the caliper piston direct short bursts of low pressure air with a blow gun through the caliper brake hose port. Use only enough air pressure to ease the piston out. CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. WARNING: NEVER ATTEMPT TO CATCH THE PISTON AS IT LEAVES THE BORE. THIS COULD RESULT IN PERSONAL INJURY. 5. Remove the C-clamp and block of wood from the caliper and clamp it over the dust boot of the first piston removed. This will seal the empty piston bore. 6. Move the padded piece of wood in front of the other piston. 7. Remove the second piston using the same procedure with short bursts of low pressure air. 8. Remove piston dust boots (2) with a suitable pry tool. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11345 CAUTION: Do not scratch piston bore while removing the seals. 9. Remove piston seals (3) from caliper (1). 10. Push caliper mounting bolt bushings (3) out of the boot seals (2) and remove the boot seals from the caliper (1). 11. Remove caliper bleed screw. Inspection - Heavy Duty (HD) INSPECTION - HEAVY DUTY (HD) The piston is made from a phenolic resin (plastic material) and should be smooth and clean. The piston must be replaced if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing. CAUTION: If the caliper piston is replaced, install the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different. The bore can be lightly polished with a brake hone (3) to remove very minor surface imperfections. The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.025 mm (0.001 inch). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11346 Light Duty (LD) LIGHT DUTY (LD) CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry. 1. Lubricate caliper pistons, piston seals and piston bores with clean, fresh brake fluid. NOTE: Verify seal is fully seated and not twisted. 2. Install new piston seals (2) into caliper bores (1). 3. Leave boot (1) dry and slip onto end of piston (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11347 NOTE: The dust boot lip must be inserted before the piston 4. Slightly pull out lip portion of piston boot (3) so it protrudes past the bottom of the piston (2) and work lip into outermost groove on caliper housing (1). 5. Carefully press the lip (3) into the groove with a suitable tool (4) Avoid using sharp-edged tools This will ensure that the lip is nested into the groove all around before pushing the piston into the bore. 6. Press the piston fully into the bore using special tool C3716-A seal installer (3) with C-4171 Handle (1). 7. Once the piston is pressed into the bottom of the bore, Check to see that the dust boot bellows are not inflated with air. If needed, push in between the dust boot and piston to expel any trapped air. Heavy Duty (HD) HEAVY DUTY (HD) CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry. 1. Lubricate caliper pistons, piston seals and piston bores with clean, fresh brake fluid. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11348 NOTE: Verify seal is fully seated and not twisted. 2. Install new piston seals (3) into caliper bores (2). 3. Lightly lubricate lip of new boot with silicone grease. Install boot on piston and work boot lip into the groove at the top of piston (3). 4. Stretch boot (2) rearward to straighten boot folds, then move boot forward until folds snap into place. 5. Install piston (3) into caliper bore and press piston down to the bottom of the caliper bore by hand or with hammer handle. 6. Seat dust boot in caliper (2) with Handle C-4171 (1) and Installer (3): - 54 mm caliper: Installer C-3716-A 7. Install the second piston and dust boot. 8. Lubricate caliper mounting bolt bushings, boot seals and bores with Mopar brake grease or Dow Corning(R) 807 grease only. CAUTION: Use of alternative grease may cause damage to the boots seals. 9. Install the boot seals into the caliper seal bores and center the seals in the bores. 10. Install mounting bolt bushings into the boot seals and insure seal lip is engaged into the bushing grooves at either end of the bushing. 11. Install caliper bleed screw. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal Brake Pad: Service and Repair Removal Heavy Duty (HD) HEAVY DUTY (HD) 1. Raise and support vehicle. 2. Remove the wheel and tire assemblies. 3. Compress the caliper. 4. Remove the caliper. 5. Remove the caliper by tilting the top up and off the caliper adapter. NOTE: Do not allow brake hose to support caliper assembly. 6. Support and hang the caliper. 7. Remove the inboard brake shoe (1) from the caliper adapter (2). 8. Remove the outboard brake shoe (1) from the caliper adapter (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal > Page 11353 NOTE: Anti-rattle springs are not interchangeable. 9. Remove the top anti-rattle springs (2) from the caliper adapter (1). 10. Remove the bottom anti-rattle springs (2) from the caliper adapter (1). Light Duty (LD) LIGHT DUTY (LD) 1. Raise and support vehicle. 2. Remove the wheel and tire assemblies. 3. Compress the caliper (2). 4. Remove the caliper slide pin bolts (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal > Page 11354 5. Remove the caliper (1) from the caliper adapter (2). NOTE: Do not allow brake hose to support caliper assembly. 6. Support and hang the caliper. 7. Remove the inboard brake pad (4) from the caliper adapter (1). 8. Remove the outboard brake pad (2) from the caliper adapter (1). 9. Remove the anti-rattle clips (1) from the pad (2). Rear Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal > Page 11355 REAR 1. Raise and support the vehicle. 2. Remove the rear wheel and tire assemblies. 3. Compress the caliper. 4. Remove caliper slide bolts (3). NOTE: Do not allow brake hose to support caliper assembly. 5. Remove the caliper (3) and then tilt the top up and off the caliper adapter. 6. Remove inboard brake shoe (1) from the caliper adapter (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal > Page 11356 7. Remove outboard brake shoe (1) from caliper adapter (2). NOTE: Anti-rattle springs are not interchangeable. 8. Remove the top anti-rattle spring (2) from the caliper adapter (1). 9. Remove the top anti-rattle spring (2) from the caliper adapter (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal > Page 11357 Brake Pad: Service and Repair Installation Heavy Duty (HD) HEAVY DUTY (HD) 1. Bottom pistons in caliper bore with C-clamp. Place an old brake shoe between a C-clamp and caliper piston. 2. Clean caliper mounting adapter (1) and anti-rattle springs (2). 3. Lubricate anti-rattle springs with Mopar brake grease. NOTE: Anti-rattle springs are not interchangeable. 4. Install new top anti-rattle springs (2). 5. Install new bottom anti-rattle springs (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal > Page 11358 6. Install inboard brake shoe (1) in adapter (2). 7. Install outboard brake shoe (1) in adapter (2). 8. Tilt the top of the caliper over rotor and under adapter. Then push the bottom of the caliper down onto the adapter. 9. Install caliper. 10. Install wheel and tire assemblies and lower vehicle. 11. Apply brakes several times to seat caliper pistons and brake shoes and obtain firm pedal. 12. Top off master cylinder fluid level. Light Duty (LD) LIGHT DUTY (LD) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal > Page 11359 1. Bottom pistons in caliper bore with C-clamp. Place an old brake shoe between a C-clamp and caliper piston. 2. Clean caliper mounting adapter. 3. Install new anti-rattle clips (1) to the brake pads (2). 4. Install inboard brake pad (4) in adapter (1). 5. Install outboard brake pad (2) in adapter (1). 6. Install the caliper (1) over rotor, Then push the caliper onto the adapter (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal > Page 11360 7. Install caliper slide pin bolts (4). 8. Install wheel and tire assemblies and lower vehicle. 9. Apply brakes several times to seat caliper pistons and brake shoes and obtain firm pedal. 10. Top off master cylinder fluid level. Rear REAR 1. Clean caliper mounting adapter (1) and anti-rattle springs (2). 2. Lubricate anti-rattle springs with Mopar brake grease. NOTE: Anti-rattle springs are not interchangeable. 3. Install new top anti-rattle spring (2). 4. Install new bottom anti-rattle spring (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal > Page 11361 5. Install inboard brake shoe (1) in adapter (2). 6. Install outboard brake shoe (1) in adapter (2). 7. Tilt the bottom of the caliper (3) over rotor (1) and under adapter. Then push the top of the caliper down onto the adapter. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal > Page 11362 8. Install caliper (6). 9. Install wheel and tire assemblies and lower vehicle. 10. Apply brakes several times to seat caliper pistons and brake shoes and obtain firm pedal. 11. Top off master cylinder fluid level. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications BASE BRAKE Base Brake (Part 1) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 11366 Base Brake (Part 2) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Standard Procedure Brake Rotor/Disc: Testing and Inspection Standard Procedure STANDARD PROCEDURE NOTE: A hub mounted on-vehicle lathe is highly recommended. This type of lathe trues the rotor to the vehicles hub/bearing. The disc brake rotor can be machined if scored or worn. The on-vehicle lathe must machine both sides of the rotor simultaneously with dual cutter heads. The rotor mounting surface must be clean before placing on the on-vehicle lathe. Equipment capable of machining only one side at a time may produce a tapered rotor This type of rotor machining is not recommended. NOTE: Proper wheel torque is also critical to help prevent any warping of the disc brake rotor. CAUTION: Brake rotors that do not meet minimum thickness specifications before or after machining must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Standard Procedure > Page 11369 Brake Rotor/Disc: Testing and Inspection Disc Brake Rotor DISC BRAKE ROTOR The rotor braking surfaces should not be refinished unless necessary. Light surface rust and scale can be removed with a lathe equipped with dual sanding discs. The rotor surfaces can be restored by machining with a disc brake lathe if surface scoring and wear are light. Replace the rotor for the following conditions: - Severely Scored - Tapered - Hard Spots - Cracked - Below Minimum Thickness ROTOR MINIMUM THICKNESS Measure rotor thickness at the center of the brake shoe contact surface. Replace the rotor if below minimum thickness, or if machining would reduce thickness below the allowable minimum. Rotor minimum thickness is usually specified on the rotor hub. The specification is either stamped or cast into the hub surface. ROTOR RUNOUT Check rotor lateral runout with dial indicator C-3339 (1). Excessive lateral runout will cause brake pedal pulsation and rapid, uneven wear of the brake shoes. Position the dial indicator plunger approximately 25.4 mm (1 in.) inward from the rotor edge. NOTE: Be sure wheel bearing has zero end play before checking rotor runout. Maximum allowable rotor runout is 0.131 mm (0.005 in.) HD. Maximum allowable rotor runout is 0.050 mm (0.002 in.) LD. ROTOR THICKNESS VARIATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Standard Procedure > Page 11370 Variations in rotor thickness will cause pedal pulsation, noise and shudder. Measure rotor thickness at 6 to 12 points around the rotor face. Position the micrometer (1) approximately 25.4 mm (1 in.) from the rotor (2) outer circumference for each measurement. Thickness should not vary by more than 0.015 mm (0.0059 in.) from point-to-point on the rotor. Machine or replace the rotor if necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Removal Brake Rotor/Disc: Service and Repair Removal Front - HD FRONT - HD 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. NOTE: Do not allow brake hose to support caliper adapter assembly. 3. Remove the caliper from the steering knuckle and remove caliper adapter assembly. 4. Remove the extension to the rotor nuts HD DRW ONLY. 5. Remove the rotor from the hub/bearing wheel studs. Front - LD FRONT - LD 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the caliper (1) with the adaptor bolts (5) from the steering knuckle (4) and remove caliper adapter assembly (1). NOTE: Do not allow brake hose to support caliper adapter assembly (1). 4. Remove the rotor (2) from the hub/bearing (3). Rear REAR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Removal > Page 11373 1. Raise and support the vehicle 2. Remove the tire and wheel assembly. 3. Remove the disc brake caliper (3). 4. Remove the caliper adapter (2) bolts. 5. Remove the retaining clips and rotor assembly (1). Rear Dual Wheels REAR DUAL WHEELS 1. Raise and support the vehicle 2. Remove the tire and wheel assembly. 3. Remove the disc brake caliper. 4. Remove the caliper adapter bolts. 5. Remove the rear axle shaft from the housing on dual rear wheels. 6. Remove the hub and rotor assembly. 7. Disassemble the hub from the rotor if needed by removing the bolts (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Removal > Page 11374 Brake Rotor/Disc: Service and Repair Installation Front - HD FRONT - HD 1. Install the hub extension and nuts to the front rotor. Tighten nuts to 130 Nm (96 ft.lbs). HD DRW ONLY. 2. Install the rotor onto the hub/bearing wheel studs. 3. Install the caliper adapter assembly and tighten adapter bolts to: 4. Install the wheel and tire assembly. 5. Apply the brakes several times to seat brake pads. Be sure to obtain firm pedal before moving vehicle. Front - LD FRONT - LD 1. Install the rotor (2) onto the hub/bearing (3). 2. Install the caliper adapter assembly (1) and tighten adapter bolts (5) to 176 Nm (130 ft.lbs.). 3. Install the wheel and tire assembly. 4. Apply the brakes several times to seat brake pads. Be sure to obtain firm pedal before moving vehicle. Rear REAR 1. Install the rotor (1) to the axleshaft. 2. Install the caliper adapter (2). 3. Install the caliper adapter bolts and tighten the mounting bolts to 135 Nm (100 ft.lbs) LD or 197 Nm (145 ft.lbs) HD. 4. Install the disc brake caliper (3). 5. Install the tire and wheel assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Removal > Page 11375 6. Lower the vehicle. Rear Dual Wheels REAR DUAL WHEELS 1. Install the hub to the rotor. Tighten the bolts (1) to 128 Nm (95 ft. lbs.). 2. Install the hub and rotor assembly. 3. Install the rear axle shaft to the housing with dual wheels. 4. Install the caliper adapter bolts 197 Nm (145 ft.lbs) LD. 5. Install the disc brake caliper. 6. Install the tire and wheel assembly. 7. Lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Manual Bleeding Brake Bleeding: Service and Repair Manual Bleeding MANUAL BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. 1. Remove reservoir filler caps and fill reservoir. 2. If calipers were overhauled, open all caliper bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. 3. Attach one end of bleed hose (1) to bleed screw and insert opposite end in glass container (2) partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. NOTE: Bleed procedure should be in this order (1) Right rear (2) Left rear (3) Right front (4) Left front. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. 5. Before moving the vehicle verify the pedal is firm and not mushy. 6. Top off the brake fluid and install the reservoir cap. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 11381 Brake Bleeding: Service and Repair Pressure Bleeding PRESSURE BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15-20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 11382 Brake Bleeding: Service and Repair Master Cylinder MASTER CYLINDER BLEEDING A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. 1. Mount master cylinder in vise. 2. Attach bleed tubes to cylinder outlet ports (1). Then position each tube end into reservoir (2). 3. Fill reservoir with fresh brake fluid. 4. Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 11383 Brake Bleeding: Service and Repair ABS Brake Bleeding ABS BRAKE BLEEDING ABS system bleeding requires conventional bleeding methods plus use of a scan tool. The procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the HCU pump and solenoids. A second base brake bleeding procedure is then required to remove any air remaining in the system. 1. Perform base brake bleeding. 2. Connect scan tool to the Data Link Connector. 3. Select ANTILOCK BRAKES, followed by MISCELLANEOUS, then ABS BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 11384 Brake Bleeding: Service and Repair Booster-Hydro-Boost Brake BLEEDING The hydraulic booster is generally self-bleeding, this procedure will normally bleed the air from the booster. Normal driving and operation of the unit will remove any remaining trapped air. 1. Fill power steering pump reservoir. 2. Disconnect fuel shutdown relay and crank the engine for several seconds, Refer to Fuel System for relay location and WARNING. 3. Check fluid level and add if necessary. 4. Connect fuel shutdown relay and start the engine. 5. Turn the steering wheel slowly from lock to lock twice. 6. Stop the engine and discharge the accumulator by depressing the brake pedal 5 times. 7. Start the engine and turn the steering wheel slowly from lock to lock twice. 8. Turn off the engine and check fluid level and add if necessary. NOTE: If fluid foaming occurs, wait for foam to dissipate and repeat steps 7 and 8. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Description and Operation > Description Brake Caliper: Description and Operation Description Light Duty (LD) Calipers LIGHT DUTY (LD) CALIPERS NOTE: Petroleum based grease should not be used on any of the rubber components of the caliper, Use only Non-Petroleum based grease. The calipers are a dual piston type. The calipers are free to slide laterally, this allows continuous compensation for lining wear. Heavy Duty (HD) Calipers HEAVY DUTY (HD) CALIPERS The calipers are a dual piston type in the front & rear. The calipers are free to slide laterally, this allows continuous compensation for lining wear. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Description and Operation > Description > Page 11389 Brake Caliper: Description and Operation Operation DISC BRAKE CALIPER When the brakes are applied fluid pressure is exerted against the caliper piston (2). The fluid pressure is exerted equally and in all directions. This means pressure exerted against the caliper piston and within the caliper bore will be equal. Fluid pressure applied to the piston is transmitted directly to the inboard brake pad (5). This forces the pad lining against the inner surface of the disc brake rotor. At the same time, fluid pressure within the piston bore forces the caliper to slide inward on the mounting bolts. This action brings the outboard brake pad lining (6) into contact with the outer surface of the disc brake rotor. In summary, fluid pressure acting simultaneously on both piston and caliper, produces a strong clamping action. When sufficient force is applied, friction will attempt to stop the rotors from turning and bring the vehicle to a stop. Application and release of the brake pedal generates only a very slight movement of the caliper and piston. Upon release of the pedal, the caliper and piston return to a rest position. The brake pads do not retract an appreciable distance from the rotor. In fact, clearance is usually at, or close to zero. The reasons for this are to keep road debris from getting between the rotor and lining and in wiping the rotor surface clear each revolution. The caliper piston seal (4) controls the amount of piston (2) extension needed to compensate for normal lining wear. During brake application, the seal is deflected outward by fluid pressure and piston movement (6). When the brakes (and fluid pressure) are released, the seal relaxes and retracts the piston (3). The amount of piston retraction is determined by the amount of seal deflection. Generally the amount is just enough to maintain contact between the piston and inboard brake pad. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement Brake Caliper: Removal and Replacement Front - Heavy Duty (HD) FRONT - HEAVY DUTY (HD) CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system. 2. Raise and support the vehicle. 3. Remove the tire and wheel assembly. 4. Compress the disc brake caliper. 5. Remove the banjo bolt and discard the copper washer. 6. Remove the caliper slide bolts. 7. Remove the disc brake caliper. Front - Light Duty (LD) FRONT - LIGHT DUTY (LD) CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose with result. Provide a suitable support to hang the caliper securely. 1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system. 2. Raise and support the vehicle. 3. Remove the tire and wheel assembly. 4. Compress the disc brake caliper (6). 5. Remove the banjo bolt (4) and discard the copper washers. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11392 6. Remove the caliper slide pin bolts (2). 7. Remove the disc brake caliper (1) from the caliper adapter (2). 8. Remove the caliper slide pins from the adapter. Rear REAR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11393 CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system. 2. Raise and support vehicle. 3. Remove the wheel and tire assembly. 4. Drain small amount of fluid from master cylinder brake reservoir with suction gun. 5. Remove the brake hose banjo bolt and discard the copper washers if replacing caliper. 6. Remove the caliper slide bolts (3). 7. Remove the caliper (6) from vehicle. Front - Heavy Duty (HD) FRONT - HEAVY DUTY (HD) NOTE: Install a new copper washers on the banjo bolt when installing 1. Install the disc brake caliper. CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt. 2. Install the banjo bolt with new copper washers to the caliper. Tighten to 27 Nm (20 ft. lbs.) 3. Install the caliper slide pin bolts. tighten to 32 Nm (24 ft. lbs.) 4. Remove the prop rod. 5. Bleed the area of repair for the brake system, If a proper pedal is not felt during bleeding an area of repair then a base bleed system must be performed. 6. Install the tire and wheel assembly 7. Lower the vehicle. Front - Light Duty (LD) FRONT - LIGHT DUTY (LD) NOTE: Petroleum based grease should not be used on any of the rubber components of the caliper, Use only Non-Petroleum based grease. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11394 NOTE: Clean slide pin bores thoroughly to remove any old grease. NOTE: Use grease packets included with kit or Dow Corning-807(R) grease. 1. Thoroughly coat the new slide pins (3) on all working surfaces. 2. Install the boot (2) onto the slide pin (3) and then insert into the adapter (1). 3. Push the pin (3) all the way into the adapter (1) and carefully expel the trapped air by gently pushing on the boot (2) near the slide pin head (3). NOTE: Install a new copper washers on the banjo bolt when installing 4. Install the disc brake caliper (1) to the brake caliper adapter (2). 5. Install the banjo bolt (4) with new copper washers to the caliper (6). Tighten to 28 Nm (250 in. lbs.) 6. Install the caliper slide pin bolts (2). Tighten to 32 Nm (24 ft. lbs.) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11395 7. Remove the prop rod. 8. Bleed the area of repair for the brake system, If a proper pedal is not felt during bleeding an area of repair then a base bleed system must be performed.. 9. Install the tire and wheel assembly. 10. Lower the vehicle. Rear REAR 1. Install caliper (6) to the caliper adapter (1). 2. Coat the caliper mounting slide pin bolts (3) with silicone grease. Then install and tighten the bolts to 30 Nm (22 ft. lbs.). 3. Install the brake hose banjo bolt if removed. 4. Install the brake hose (4) to the caliper (6) with new seal washers and tighten fitting bolt to 27 Nm (245 in. lbs.). CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt. 5. Remove the prop rod from the brake pedal. 6. Bleed the area of repair for the brake system, If a proper pedal is not felt during bleeding an area of repair then a base bleed system must be performed.. 7. Install the wheel and tire assemblies. 8. Remove the supports and lower the vehicle. 9. Verify a firm pedal before moving the vehicle. Front FRONT 1. Raise and support the vehicle. 2. Remove the front wheel and tire assembly. 3. Remove the caliper slide pin bolts (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11396 4. Remove the disc brake caliper (1) from the adapter (2). CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 5. Remove the inboard (4) and outboard (2) brake pads. 6. Remove the caliper adapter mounting bolts (5). 7. Remove the caliper slide pins from the adapter. Rear REAR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11397 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Drain a small amount of fluid from master cylinder brake reservoir with a clean suction gun. 4. Bottom the caliper pistons into the caliper by prying the caliper over. 5. Remove the caliper slide bolts. 6. Remove the disc brake caliper from the mount. CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 7. Remove the inboard and outboard brake pads (1). 8. Remove the anti-rattle clips (2). 9. Remove the caliper adapter mounting bolts (4). 10. Remove the caliper adapter. Front FRONT NOTE: Petroleum based grease should not be used on any of the rubber components of the caliper, Use only a Non-Petroleum based grease, such as Dow Corning-807(R) grease. NOTE: Clean slide pin bores thoroughly to remove any old grease. NOTE: Use grease packets included with kit or Dow Corning-807(R) grease. 1. Thoroughly coat the new slide pins (3) on all working surfaces. 2. Install the boot (2) onto the slide pin (3) and then insert into the adapter (1). 3. Push the pin (3) all the way into the adapter (1) and carefully expel the trapped air by gently pushing on the boot (2) near the slide pin head (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11398 4. Install the caliper adapter mounting bolts (5). Tighten the mounting bolts to 176 Nm (130 ft.lbs) LD or Tighten the mounting bolts to 339 Nm (250 ft.lbs) HD. 5. Install the inboard (4) and outboard (2) pads. 6. Install the caliper (2) and the caliper slide pin bolts (4). 7. Install the tire and wheel assembly. Rear REAR 1. Install the caliper adapter mounting bolts (4). Tighten the mounting bolts to 135 Nm (100 ft.lbs) LD or tighten to 197 Nm (145 ft.lbs.) HD. 2. Install the anti-rattle clips (2). 3. Install the inboard and outboard pads (1). 4. Install the caliper mounting bolts. 5. Install the tire and wheel assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11399 Removal REAR 1. Remove wheel and tire assembly. 2. Remove the disc brake caliper. 3. Remove the caliper adapter. 4. Remove the rotor. 5. Remove the axle shaft. 6. Remove the park brake shoes. 7. Remove the parking brake cable from the brake lever. 8. Remove the bolts (3) attaching the support plate to the axle and remove the support plate. 9. Remove the caliper adapter mount (1) from the axle housing (2). Installation INSTALLATION 1. Install the caliper adapter mount (1) on the axle housing (2). 2. Install support plate on axle flange. Tighten attaching bolts (3) to 68 Nm (50 ft. lbs.) LD or tighten to 203 Nm (150 ft.lbs.) HD. 3. Install parking brake cable in the brake lever. 4. Install the park brake shoes. 5. Install axle shaft. 6. Adjust brake shoes to drum with brake gauge. 7. Install the rotor. 8. Install the caliper adapter. 9. Install the caliper. 10. Install wheel and tire assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11400 Brake Caliper: Overhaul Light Duty (LD) LIGHT DUTY (LD) 1. Drain the brake fluid from caliper. 2. C-clamp (2) a block of wood (1) over one piston. 3. Take another piece of wood and pad it with one-inch thickness of shop towels (2). Place this piece in the outboard shoe side of the caliper in front of the other piston. This will cushion and protect caliper piston during removal. 4. To remove the caliper piston direct short bursts of low pressure air with a blow gun through the caliper brake hose port. Use only enough air pressure to ease the piston out. CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. WARNING: Never attempt to catch the piston as it leaves the bore. This could result in personal injury. 5. Remove the C-clamp and block of wood from the caliper and clamp it over the dust boot of the first piston removed. This will seal the empty piston bore. 6. Move the padded piece of wood in front of the other piston. 7. Remove the second piston using the same procedure with short bursts of low pressure air. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11401 8. Remove piston dust boots (2) by hand. CAUTION: Do not scratch piston bore while removing the seals. 9. Remove the lip seal from the groove (4) with a pick tool (3). 10. Remove piston seals (2) from caliper (1) by hand. Heavy Duty (HD) HEAVY DUTY (HD) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11402 1. Drain the brake fluid from caliper. 2. C-clamp (2) a block of wood (1) over one piston. 3. Take another piece of wood and pad it with one-inch thickness of shop towels (2). Place this piece in the outboard shoe side of the caliper in front of the other piston. This will cushion and protect caliper piston during removal. 4. To remove the caliper piston direct short bursts of low pressure air with a blow gun through the caliper brake hose port. Use only enough air pressure to ease the piston out. CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. WARNING: NEVER ATTEMPT TO CATCH THE PISTON AS IT LEAVES THE BORE. THIS COULD RESULT IN PERSONAL INJURY. 5. Remove the C-clamp and block of wood from the caliper and clamp it over the dust boot of the first piston removed. This will seal the empty piston bore. 6. Move the padded piece of wood in front of the other piston. 7. Remove the second piston using the same procedure with short bursts of low pressure air. 8. Remove piston dust boots (2) with a suitable pry tool. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11403 CAUTION: Do not scratch piston bore while removing the seals. 9. Remove piston seals (3) from caliper (1). 10. Push caliper mounting bolt bushings (3) out of the boot seals (2) and remove the boot seals from the caliper (1). 11. Remove caliper bleed screw. Inspection - Heavy Duty (HD) INSPECTION - HEAVY DUTY (HD) The piston is made from a phenolic resin (plastic material) and should be smooth and clean. The piston must be replaced if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing. CAUTION: If the caliper piston is replaced, install the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different. The bore can be lightly polished with a brake hone (3) to remove very minor surface imperfections. The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.025 mm (0.001 inch). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11404 Light Duty (LD) LIGHT DUTY (LD) CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry. 1. Lubricate caliper pistons, piston seals and piston bores with clean, fresh brake fluid. NOTE: Verify seal is fully seated and not twisted. 2. Install new piston seals (2) into caliper bores (1). 3. Leave boot (1) dry and slip onto end of piston (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11405 NOTE: The dust boot lip must be inserted before the piston 4. Slightly pull out lip portion of piston boot (3) so it protrudes past the bottom of the piston (2) and work lip into outermost groove on caliper housing (1). 5. Carefully press the lip (3) into the groove with a suitable tool (4) Avoid using sharp-edged tools This will ensure that the lip is nested into the groove all around before pushing the piston into the bore. 6. Press the piston fully into the bore using special tool C3716-A seal installer (3) with C-4171 Handle (1). 7. Once the piston is pressed into the bottom of the bore, Check to see that the dust boot bellows are not inflated with air. If needed, push in between the dust boot and piston to expel any trapped air. Heavy Duty (HD) HEAVY DUTY (HD) CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry. 1. Lubricate caliper pistons, piston seals and piston bores with clean, fresh brake fluid. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 11406 NOTE: Verify seal is fully seated and not twisted. 2. Install new piston seals (3) into caliper bores (2). 3. Lightly lubricate lip of new boot with silicone grease. Install boot on piston and work boot lip into the groove at the top of piston (3). 4. Stretch boot (2) rearward to straighten boot folds, then move boot forward until folds snap into place. 5. Install piston (3) into caliper bore and press piston down to the bottom of the caliper bore by hand or with hammer handle. 6. Seat dust boot in caliper (2) with Handle C-4171 (1) and Installer (3): - 54 mm caliper: Installer C-3716-A 7. Install the second piston and dust boot. 8. Lubricate caliper mounting bolt bushings, boot seals and bores with Mopar brake grease or Dow Corning(R) 807 grease only. CAUTION: Use of alternative grease may cause damage to the boots seals. 9. Install the boot seals into the caliper seal bores and center the seals in the bores. 10. Install mounting bolt bushings into the boot seals and insure seal lip is engaged into the bushing grooves at either end of the bushing. 11. Install caliper bleed screw. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Brake Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 11411 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 11412 Brake Fluid: Specifications BRAKE FLUID Mopar DOT 3 and SAE J1703 or equivalent. NOTE: If DOT 3 is not available, the DOT 4 is acceptable. Use only recommended brake fluids. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 11413 Brake Fluid: Description and Operation BRAKE FLUID The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum-based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 11414 Brake Fluid: Testing and Inspection BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If brake fluid is contaminated, drain and thoroughly flush system. Replace master cylinder, proportioning valve, caliper seals, wheel cylinder seals, Antilock Brakes hydraulic unit and all hydraulic fluid hoses. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 11415 Brake Fluid: Service and Repair BRAKE FLUID LEVEL Always clean the master cylinder reservoir (1) and cap (2) before checking fluid level. If not cleaned, dirt could enter the fluid. The fluid fill level is indicated on the side of the master cylinder reservoir (1). The correct fluid level is to the MAX indicator on the side of the reservoir. If necessary, add fluid to the proper level. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Component ID: 389 Component : SENSOR-BRAKE FLUID LEVEL Connector: Name : SENSOR-BRAKE FLUID LEVEL Color : BLACK # of pins : 2 Pin Description Circuit 1 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/OR 2 GROUND Z420 20BK/OR Component Location - 32 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 11419 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 11420 Brake Fluid Level Sensor/Switch: Diagrams Component ID: 389 Component : SENSOR-BRAKE FLUID LEVEL Connector: Name : SENSOR-BRAKE FLUID LEVEL Color : BLACK # of pins : 2 Pin Description Circuit 1 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/OR 2 GROUND Z420 20BK/OR Component Location - 32 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 11421 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Procedures Brake Hose/Line: Procedures Double Inverted Flaring DOUBLE INVERTED FLARING A preformed metal brake tube is recommended and preferred for all repairs. However, double-wall steel tube can be used for emergency repair when factory replacement parts are not readily available. 1. Cut off damaged tube with Tubing Cutter. 2. Ream cut edges of tubing to ensure proper flare. 3. Install replacement tube nut on the tube. 4. Insert tube in flaring tool. 5. Place gauge form over the end of the tube. 6. Push tubing through flaring tool jaws until tube contacts recessed notch in gauge that matches tube diameter. 7. Tighten the tool bar on the tube 8. Insert plug on gauge in the tube. Then swing compression disc over gauge and center tapered flaring screw in recess of compression disc. 9. Tighten tool handle until plug gauge is squarely seated on jaws of flaring tool. This will start the inverted flare. 10. Remove the plug gauge and complete the inverted flare. ISO Flaring ISO FLARING A preformed metal brake tube is recommended and preferred for all repairs. However, double-wall steel tube can be used for emergency repair when factory replacement parts are not readily available. To make a ISO flare use an ISO flaring tool kit. 1. Cut off damaged tube with Tubing Cutter. 2. Remove any burrs from the inside of the tube. 3. Install tube nut on the tube. 4. Position the tube in the flaring tool flush with the top of the tool bar (6). Then tighten the tool bar on the tube. 5. Install the correct size adaptor (1) on the flaring tool yoke screw. 6. Lubricate the adaptor (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Procedures > Page 11426 7. Align the adaptor and yoke screw over the tube. 8. Turn the yoke screw in until the adaptor is squarely seated on the tool bar. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Procedures > Page 11427 Brake Hose/Line: Removal and Replacement Rear Tube / Hose Assembly REAR TUBE / HOSE ASSEMBLY 1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system. 2. Raise and support the vehicle. 3. Remove the brake line located at the axle. 4. Remove the mounting bolt (2) for the brake hose (3) at the axle. 5. Remove the banjo bolt (1) at the caliper. 6. Remove the hose. Front Brake Hose FRONT BRAKE HOSE 1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system. 2. Raise and support vehicle. 3. Remove the tire and wheel assembly. 4. Remove the brake hose (2) from the brake line located at the frame. 5. Remove the brake hose banjo bolt (3) at the caliper. 6. Remove the mounting bolt securing the brake hose (2) to the frame and remove the wheel speed sensor wire (4) from the brake hose (2). 7. Remove the hose. Rear Brake Hose REAR BRAKE HOSE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Procedures > Page 11428 1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system. 2. Raise and support the vehicle. 3. Remove the brake line (3) from the hose (1) at the frame. 4. Remove the brake hose clip (2) at the top of the hose located at the frame. 5. Remove the vent hose (2). 6. Remove the two brake lines (3) at the bottom of the hose (1) located at the axle. 7. Remove the mounting bolt for the brake hose at the axle. 8. Remove the hose. Rear Tube / Hose Assembly REAR TUBE / HOSE ASSEMBLY 1. Install the hose (3). 2. Install the banjo bolt (1) at the caliper and tighten fitting bolt to 27 Nm (245 in. lbs.). 3. Install the mounting bolt (2) for the brake hose (3) at the axle. 4. Install the brake line located at the axle. 5. Lower the vehicle and remove the support. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Procedures > Page 11429 6. Remove the prop rod from the brake pedal. 7. Bleed the area of repair for the brake system, If a proper pedal is not felt during bleeding an area of repair then a base bleed system must be performed. Front Brake Hose FRONT BRAKE HOSE 1. Install the hose (3). 2. Install the mounting bolt (1) for the brake hose (3) at the frame. 3. Install the brake hose banjo bolt at the caliper. 4. Reinstall the wheel speed sensor wire (2) to the brake hose. 5. Remove the support and lower the vehicle. 6. Remove the prop rod from the brake pedal. 7. Bleed the area of repair for the brake system, If a proper pedal is not felt during bleeding an area of repair then a base bleed system must be performed.. Rear Brake Hose REAR BRAKE HOSE 1. Install the hose (1). 2. Install the mounting bolt for the brake hose (1) at the axle. 3. Install the two brake lines (3) at the bottom of the hose located at the axle. 4. Install the vent hose (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Procedures > Page 11430 5. Install the brake hose clip (2) at the top of the hose (1) located at the frame. 6. Install the brake line (3) to the hose at the frame. 7. Lower the vehicle and remove the support. 8. Remove the prop rod from the brake pedal. 9. Bleed the area of repair for the brake system, If a proper pedal is not felt during bleeding an area of repair then a base bleed system must be performed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > HCU (Hydraulic Control Unit) Hydraulic Control Assembly - Antilock Brakes: Description and Operation HCU (Hydraulic Control Unit) Description DESCRIPTION The HCU (3) consists of a valve body, pump motor, low pressure accumulators, inlet valves, outlet valves and noise attenuators. Operation OPERATION Accumulators in the valve body store extra fluid released to the system for ABS mode operation. The pump provides the fluid volume needed and is operated by a DC type motor. The motor is controlled by the ABM. The valves modulate brake pressure during antilock braking and are controlled by the ABM. The HCU provides three channel pressure control to the front and rear brakes. One channel controls the rear wheel brakes in tandem. The two remaining channels control the front wheel brakes individually. During antilock braking, the solenoid valves are opened and closed as needed. During normal braking, the HCU solenoid valves and pump are not activated. The master cylinder and power booster operate the same as a vehicle without an ABS brake system. NOTE: The three modes mentioned below do occur but not necessarily in the order listed every time. During antilock braking, solenoid valve pressure modulation occurs in three stages, pressure increase, pressure hold, and pressure decrease. The valves are all contained in the valve body portion of the HCU. PRESSURE DECREASE The outlet valve is opened and the inlet valve is closed during the pressure decrease cycle. A pressure decrease cycle is initiated when speed sensor signals indicate high wheel slip at one or more wheels. At this point, the ABM closes the inlet then opens the outlet valve, which also opens the return circuit to the accumulators. Fluid pressure is allowed to bleed off (decrease) as needed to prevent wheel lock. Once the period of high wheel slip has ended, the ABM closes the outlet valve and begins a pressure increase or hold cycle as needed. PRESSURE HOLD Both solenoid valves are closed in the pressure hold cycle but only the inlet valve is energized. Fluid apply pressure in the control channel is maintained at a constant rate. The ABM maintains the hold cycle until sensor inputs indicate a pressure change is necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > HCU (Hydraulic Control Unit) > Page 11435 PRESSURE INCREASE The inlet valve is open and the outlet valve is closed during the pressure increase cycle. The pressure increase cycle is used to reapply thew brakes. This cycle controls re-application of fluid apply pressure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > HCU (Hydraulic Control Unit) > Page 11436 Hydraulic Control Assembly - Antilock Brakes: Description and Operation RWAL Valve Description DESCRIPTION Rear Wheel Antilock (RWAL) brake system is standard equipment on 1500 series vehicles. The RWAL brake system is designed to prevent rear wheel lock-up on virtually all types of road surfaces. RWAL braking is desirable because a vehicle which is stopped without locking the rear wheels will retain directional stability. This allows the driver to retain greater control of the vehicle during braking. The valve is located on the drivers side inner fender under the hood. The valve modulates hydraulic pressure to the rear brakes. The RWAL components include: - RWAL Valve(1) - Controller Antilock brake (CAB) - Rear Wheel Speed Sensor (WSS) Operation OPERATION When the brakes are applied, hydraulic fluid is routed from the master cylinder's secondary circuit to the RWAL valve. From there hydraulic fluid is routed to the rear brakes. The Controller Antilock Brake (CAB) contains an Electronic Variable Brake Proportioning (EVBP) control algorithm, which proportions the applied braking force to the rear wheels during braking. The EVBP function of the RWAL system takes the place of a conventional hydraulic proportioning valve. The CAB monitors the rear wheel speed through the rear wheel speed sensor and calculates an estimated vehicle deceleration. When an established deceleration threshold is exceeded, an isolation valve is closed to hold the applied brake pressure to the rear brakes constant. Upon further increases in the estimated vehicle deceleration, the isolation valve is selectively opened to increase rear brake pressure in proportion to the front brake pressure. If impending rear wheel lock-up is sensed, the CAB signals the RWAL valve to modulate hydraulic brake pressure to the rear wheels to prevent lock-up. NORMAL BRAKING Since the RWAL valve also performs the EVBP or proportioning function, vehicle deceleration under normal braking may be sufficient to trigger the EVBP function of the RWAL system without full RWAL activity as would normally occur during an impending rear wheel lock-up. As previously mentioned, the isolation valve is selectively closed and opened to increase rear brake pressure in proportion to the front brake pressure under EVBP control. Slight brake pedal pulsations may be noticed as the isolation valve is opened. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > HCU (Hydraulic Control Unit) Hydraulic Control Assembly - Antilock Brakes: Service and Repair HCU (Hydraulic Control Unit) Removal REMOVAL 1. Disconnect the battery cables from the battery. 2. Remove the battery. 3. Disconnect the electrical harness connectors. 4. Remove the brake lines from the HCU (3). 5. Remove HCU/ABM mounting bolts (1) and remove the HCU/ABM (3) from the battery tray (4). Installation INSTALLATION NOTE: If the ABM (2) is being replaced with a new ABM is must be reprogrammed with the use of a scan tool. 1. Install HCU/ABM (3) on the mounts to the battery tray (4) and Tighten the bolts to 15 Nm (11 ft. lbs.). 2. Install the brake lines to the HCU (3) and tighten to 19 Nm (170 in. lbs.). 3. Install the electrical harness connectors to the HCU/ABM (3) and push down on the release to secure the connectors. 4. Install the battery. 5. Install the battery cables to the battery. 6. Bleed ABS brake system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > HCU (Hydraulic Control Unit) > Page 11439 Hydraulic Control Assembly - Antilock Brakes: Service and Repair RWAL Valve Removal REMOVAL 1. Disconnect the battery cables from the battery. 2. Remove the battery. 3. Disconnect the electrical harness connector. 4. Remove the brake lines from the rwal valve (1). 5. Remove rwal valve mounting nuts (2) and remove the rwal valve (1). Installation INSTALLATION 1. Install rwal valve (1) and Tighten the nuts (2) to 15 Nm (11 ft. lbs.). 2. Install the brake lines to the rwal valve and tighten to 19 Nm (170 in. lbs.). 3. Install the electrical harness connector to the rwal valve and secure the connector. 4. Install the battery. 5. Install the battery cables to the battery. 6. Bleed ABS brake system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic System Junction Block > Component Information > Service and Repair > Removal Hydraulic System Junction Block: Service and Repair Removal REMOVAL 1. Remove the brake lines (1) from the junction block (2). 2. Remove the junction block (2) mounting bolt and remove the junction block from the bracket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic System Junction Block > Component Information > Service and Repair > Removal > Page 11444 Hydraulic System Junction Block: Service and Repair Installation INSTALLATION 1. Position the junction block (2) on the bracket and install the mounting bolt. Tighten the mounting bolt to 23 Nm (210 in. lbs.). 2. Install the brake lines (1) into the junction block (2) and tighten to 19-23 Nm (170-200 in. lbs.). 3. Bleed the base brake system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Description Brake Master Cylinder: Description and Operation Description DESCRIPTION A two-piece master cylinder is used on all models. The cylinder body containing the primary and secondary pistons is made of aluminum. The removable fluid reservoir is made of nylon reinforced with glass fiber. The reservoir stores reserve brake fluid for the hydraulic brake circuits and has a switch for indicating low fluid levels. The reservoir is the only serviceable component. The fluid compartments of the nylon reservoir are interconnected to permit fluid level equalization. However, the equalization feature does not affect circuit separation in the event of a front or rear brake malfunction. The reservoir compartments will retain enough fluid to operate the functioning hydraulic circuit. Care must be exercised when removing/installing the master cylinder connecting lines. The threads in the cylinder fluid ports can be damaged if care is not exercised. Start all brake line fittings by hand to avoid cross threading. The cylinder reservoir can be replaced when necessary. However, the aluminum body of the master cylinder is not a repairable component. NOTE: If diagnosis indicates that an internal malfunction has occurred, the aluminum body must be replaced as an assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Description > Page 11449 Brake Master Cylinder: Description and Operation Operation OPERATION The master cylinder bore contains a primary and secondary piston. The primary piston supplies hydraulic pressure to the front brakes. The secondary piston supplies hydraulic pressure to the rear brakes. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Page 11450 Brake Master Cylinder: Testing and Inspection MASTER CYLINDER/POWER BOOSTER 1. Start engine and check booster vacuum hose connections. A hissing noise indicates vacuum leak. Correct any vacuum leak before proceeding. 2. Stop engine and shift transmission into Neutral. 3. Pump brake pedal until all vacuum reserve in booster is depleted. 4. Press and hold brake pedal under light foot pressure. The pedal should hold firm, if the pedal falls away master cylinder is faulty (internal leakage). 5. Start engine and note pedal action. It should fall away slightly under light foot pressure then hold firm. If no pedal action is discernible, power booster, vacuum supply, or vacuum check valve is faulty. Proceed to the POWER BOOSTER VACUUM TEST. 6. If the POWER BOOSTER VACUUM TEST passes, rebuild booster vacuum reserve as follows: Release brake pedal. Increase engine speed to 1500 rpm, close the throttle and immediately turn off ignition to stop engine. 7. Wait a minimum of 90 seconds and try brake action again. Booster should provide two or more vacuum assisted pedal applications. If vacuum assist is not provided, booster is faulty. POWER BOOSTER VACUUM TEST 1. Connect vacuum gauge (6) to booster check valve (4) with short length of hose (3) and T-fitting (2). 2. Start and run engine at curb idle speed for one minute. 3. Observe the vacuum supply. If vacuum supply is not adequate, repair vacuum supply. 4. Clamp (1) hose (7) shut between intake vacuum source (5) and check valve (4). 5. Stop engine and observe vacuum gauge (6). 6. If vacuum drops more than one inch HG (33 millibars) within 15 seconds, booster diaphragm or check valve is faulty. POWER BOOSTER CHECK VALVE TEST 1. Disconnect vacuum hose from check valve (1). 2. Remove check valve (1) and valve seal (2) from booster (3). 3. Use a hand operated vacuum pump for test. 4. Apply 15-20 inches vacuum at large end of check valve. 5. Plug off the small end to prevent vacuum leakage. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Page 11451 6. Vacuum should hold steady. If gauge on pump indicates vacuum loss, check valve is faulty and should be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures Brake Master Cylinder: Procedures MASTER CYLINDER BLEEDING A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. 1. Mount master cylinder in vise. 2. Attach bleed tubes to cylinder outlet ports (1). Then position each tube end into reservoir (2). 3. Fill reservoir with fresh brake fluid. 4. Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 11454 Brake Master Cylinder: Removal and Replacement Removal REMOVAL 1. Install the prop rod on the brake pedal to keep pressure on the brake system. 2. Remove the reservoir cap (1) and siphon fluid into a drain container. 3. Remove the electrical connector from the fluid level switch (3) in the reservoir (2). 4. Remove the reservoir mounting bolt (5). 5. Remove the reservoir (2) from the master cylinder (4) by pulling upwards. 6. Remove old grommets from cylinder body. Installation INSTALLATION CAUTION: Do not use any type of tool to install the grommets. Tools may cut, or tear the grommets creating a leak problem after installation. Install the grommets using finger pressure only. 1. Lubricate the new grommets (6) with clean brake fluid and Install new grommets in cylinder body. Use finger pressure to install and seat grommets (6). 2. Start the reservoir (2) in grommets (6). Then rock the reservoir back and forth while pressing downward to seat it into the grommets. 3. Install the mounting bolt (5) for the reservoir (2) to the master cylinder (4). 4. Reconnect the electrical connector to the fluid reservoir level switch (3). 5. Remove the prop rod from the vehicle. 6. Fill and bleed base brake system. All Except Hydroboost ALL EXCEPT HYDROBOOST Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 11455 1. Depress the brake pedal five times to deplete any vacuum that may remain in the booster unit. 2. Siphon and drain the fluid from the reservoir. 3. Disconnect the electrical connector for the low fluid level. 4. Place a towel or rag under the master cylinder outlet port area to protect the vehicle from brake fluid damage. 5. Remove the brake lines (3) from the master cylinder (4). 6. Remove the mounting nuts from the master cylinder (4). 7. Remove the master cylinder (4). NOTE: Gently ease the master cylinder & reservoir assembly away from the booster, During removal the master cylinder should be kept as perpendicular to the front of the booster as possible to avoid excess interference with the booster output rod and in order not to dislodge the output rod from its seat inside the booster. Hydroboost HYDROBOOST 1. Remove the brake lines from the master cylinder. 2. Disconnect the electrical connector for the low fluid level. 3. Remove the mounting nuts (4) from the master cylinder (3). 4. Remove the master cylinder (3). NOTE: Using care remove the master cylinder directly forward in order not to dislodge the output rod from its seat inside the booster. All Except Hydroboost ALL EXCEPT HYDROBOOST NOTE: If master cylinder is replaced bleed cylinder before installation. NOTE: Make sure the output rod of the brake booster is in position and retained by a output rod retaining ring, by looking into the boosters master cylinder mounting hole. This position will enable the output rod to enter inside of the master cylinder plunger sleeve during installation. Proper position is obtained when the output rod is centered perpendicular to the master cylinder mounting hole. NOTE: Prior to installing the master cylinder assembly check that there is a vacuum seal present at the shoulder of the master cylinder flange and it's neck. A square seal must be present to ensure vacuum integrity with the booster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 11456 1. Gently install the master cylinder (9) on the booster mounting studs (4). NOTE: Take precautions to locate the master cylinder plunger over the booster output rod, before installing the master cylinder. If correctly fitted the master cylinder should slide easily onto the booster output rod before the mounting studs are engaged in the flange holes of the master cylinder. 2. Install new mounting nuts and tighten to 25 Nm (221 in. lbs.) 3. Install the brake lines and tighten to 19 Nm (170 in. lbs.) 4. Reconnect the electrical connector for the low fluid level switch. 5. Fill and bleed the base brake system. Hydroboost HYDROBOOST NOTE: If master cylinder is replaced bleed cylinder before installation. 1. Install the master cylinder (3) on the booster mounting studs. 2. Install new mounting nuts (4) and tighten to 25 Nm (221 in. lbs.) 3. Install the brake lines and tighten to 19 Nm (170 in. lbs.) 4. Reconnect the electrical connector for the low fluid level switch. 5. Fill and bleed the base brake system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Backing Plate > Component Information > Service and Repair > Removal Parking Brake Backing Plate: Service and Repair Removal REMOVAL 1. Remove wheel and tire assembly. 2. Remove the disc brake caliper. 3. Remove the caliper adapter. 4. Remove the rotor. 5. Remove the axle shaft. 6. Remove the park brake shoes. 7. Remove the parking brake cable from the brake lever. 8. Remove the bolts (2) attaching the support plate (1) to the axle and remove the support plate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Backing Plate > Component Information > Service and Repair > Removal > Page 11462 Parking Brake Backing Plate: Service and Repair Installation INSTALLATION 1. Install support plate (1) on axle flange. Tighten attaching bolts (2) to 68 Nm (50 ft. lbs.) LD or 203 Nm (150 ft.lbs) HD. 2. Install parking brake cable in the brake lever. 3. Install the park brake shoes. 4. Install axle shaft. 5. Adjust brake shoes to drum with brake gauge. 6. Install the rotor. 7. Install the caliper adapter. 8. Install the caliper. 9. Install the wheel and tire assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Adjustments Parking Brake Cable: Adjustments CABLE TENSIONER NOTE: Tensioner adjustment is only necessary when the tensioner, or a cable has been replaced or disconnected for service. When adjustment is necessary, perform adjustment only as described in the following procedure. This is necessary to avoid faulty park brake operation. 1. Raise the vehicle. 2. Back off the cable tensioner adjusting nut (5) to create slack in the cables. 3. Remove the rear wheel/tire assemblies. Then remove the brake rotors. 4. Verify the brakes are in good condition and operating properly. 5. Verify the park brake cables operate freely and are not binding, or seized. 6. Check the rear brake shoe adjustment with standard brake gauge. 7. Install the rotors and verify that the rotors rotate freely without drag. 8. Install the wheel/tire assemblies. 9. Lower the vehicle enough for access to the park brake foot pedal. Then fully apply the park brakes. NOTE: Leave park brakes applied until adjustment is complete. 10. Raise the vehicle again. 11. Mark the tensioner rod 6.35 mm (1/4 in.) from edge of the tensioner (2). 12. Tighten the adjusting nut (5) on the tensioner rod until the mark is no longer visible. CAUTION: Do not loosen, or tighten the tensioner adjusting nut for any reason after completing adjustment. 13. Lower the vehicle until the rear wheels are 15-20 cm (6-8 in.) off the shop floor. 14. Release the park brake foot pedal and verify that rear wheels rotate freely without drag. Then lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal Parking Brake Cable: Service and Repair Removal Front Parking Brake Cable FRONT PARKING BRAKE CABLE 1. Raise and support vehicle. 2. Lockout the parking brake cable (2). 3. Loosen adjusting nut to create slack in front cable. 4. Remove the front cable from the cable connector. 5. Compress cable end fitting at underbody bracket and remove the cable from the bracket. 6. Lower vehicle. 7. Push ball end of cable out of pedal clevis with small screwdriver. 8. Compress cable end fitting at the pedal bracket (1) and remove the cable (2). 9. Remove the left cowl trim and sill plate. 10. Pull up the carpet and remove the cable from the body clip. 11. Pull up on the cable and remove the cable with the body grommet. Rear Park Brake Cable REAR PARK BRAKE CABLE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 11468 1. Raise and support the vehicle. 2. Lockout the parking brake cable (2). 3. Loosen cable adjuster nut. 4. Remove the rear park brake cable from the intermediate park brake cable. 5. Compress tabs on cable end fitting on the rear park brake cable to the frame mount bracket. Then pull the cable through the bracket. 6. Disengage the park brake cable (2) from behind the rotor assembly.. 7. Compress cable tabs on each cable end fitting at the brake cable support plate. 8. Remove the cables from the brake cable support plates. Right Rear Cable RIGHT REAR CABLE 1. Raise and support the vehicle. 2. Lockout the parking brake cable (2). 3. Loosen the brake cable at the equalizer and adjuster nut. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 11469 4. Remove the right cable from the front cable. 5. Remove the right cable from the equalizer. 6. Remove the cable from the frame bracket. 7. Remove the cable from the axle bracket. 8. Remove the cable bracket from the shock bracket. 9. Remove the brake cable (4) from the brake lever (3). Left Rear Cable LEFT REAR CABLE 1. Raise and support the vehicle. 2. Lockout the parking brake cable (2). 3. Loosen the brake cable at the equalizer and adjuster nut. 4. Remove the left brake cable from the equalizer. 5. Remove the brake cable (4) from the frame bracket. 6. Remove the brake cable (4) from the brake lever. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 11470 Parking Brake Cable: Service and Repair Installation Front Parking Brake Cable FRONT PARKING BRAKE CABLE 1. From inside the vehicle, insert the cable end fitting (2) into the hole in the pedal assembly (1). 2. Seat the cable retainer in the pedal assembly (1). 3. Engage the cable ball end in clevis on the pedal assembly. 4. Route the cable through the floorpan and install the body grommet. 5. Place the carpet down and install the left cowl trim and sill plate. 6. Raise and support the vehicle. 7. Route the cable through the underbody bracket and seat the cable end fitting in the bracket. 8. Connect the cable to the cable connector. 9. Perform the park brake adjustment procedure. 10. Lower the vehicle. Rear Park Brake Cable REAR PARK BRAKE CABLE 1. Push each cable end (2) through the brake cable support plate hole until the cable end fitting tabs lock into place. NOTE: Pull on the cable to ensure it is locked into place. 2. Push the cable through the frame bracket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 11471 3. Lock the left cable end fitting tabs into the frame bracket hole. 4. Install the rear cables into the tensioner rod behind the rear of the brake assembly. 5. Install the cable to the intermediate cable connector. 6. Release and remove the lock out device. 7. Perform the park brake adjustment procedure. 8. Remove the supports and lower the vehicle. Right Rear Cable RIGHT REAR CABLE 1. Install the brake cable (2) to the brake lever (3). 2. Install the cable bracket to the shock bracket. 3. Install the cable to the axle bracket. 4. Install the cable to the frame bracket. 5. Install the right cable to the equalizer. 6. Install the right cable to the front cable. 7. Adjust the brake cable at the equalizer and using the adjuster nut. Left Rear Cable LEFT REAR CABLE 1. Install the brake cable (4) to the brake lever. 2. Install the brake cable to the frame bracket. 3. Install the left brake cable to the equalizer. 4. Adjust the brake cable at the equalizer and adjuster nut. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair > Pedal Parking Brake Pedal: Service and Repair Pedal Removal REMOVAL 1. Release the parking brake. 2. Raise the vehicle. 3. Loosen the cable tensioner nut at the equalizer to create slack in the front cable. 4. Lower the vehicle. 5. Remove the knee bolster. 6. Disconnect the brake lamp wire from the switch on the pedal assembly (2). 7. Roll the carpet back, loosen the front cable grommet from the floorpan and the cable retainer. 8. Disengage the release rod (1) from the arm on the pedal assembly (2). 9. Remove the bolts/nuts from the pedal assembly (2) and remove the assembly. Installation INSTALLATION 1. Position the replacement pedal assembly (1) on the dash and cowl. 2. Install the bolts/nuts (2) and tighten to 28 Nm (21 ft. lbs.). 3. Install the park brake release rod. 4. Connect the front cable to the arm on the pedal assembly (1). 5. Install the front cable grommet into the floorpan and the cable retainer, roll the carpet back. 6. Connect the wires to the brake lamp switch. 7. Install the knee bolster. 8. Raise the vehicle. 9. Adjust the parking brake cable tensioner. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair > Pedal > Page 11476 Parking Brake Pedal: Service and Repair Handle-Release Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Reach under the driver side outboard end of the instrument panel to access and unsnap the plastic retainer clip that secures the park brake release linkage rod to the park brake mechanism on the left cowl side inner panel. 3. Disengage the park brake release linkage rod end from the park brake mechanism. 4. Lift the park brake release handle to access and unsnap the plastic retainer clip that secures the park brake release linkage rod to the lever on the back of the park brake release handle. 5. Lower the park brake release handle and reach under the driver side outboard end of the instrument panel to disengage the park brake release linkage rod end from the lever on the back of the park brake release handle. 6. Lift the park brake release handle to access the handle mounting bracket. 7. Using a trim stick (4) or another suitable wide flat-bladed tool, gently pry each of the park brake release handle (6) mounting bracket latch tabs (5) away from the retaining notches in the instrument panel receptacle. 8. With both of the park brake release handle mounting bracket latches released, slide the handle and bracket assembly down and out of the instrument panel receptacle. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair > Pedal > Page 11477 1. Position the park brake release handle to the instrument panel. 2. Slide the handle and bracket assembly up into the instrument panel receptacle until both of the park brake release handle (6) mounting bracket latches are engaged with the notches in the instrument panel receptacle. 3. Lower the park brake release handle and reach under the driver side outboard end of the instrument panel to engage the park brake release linkage rod end with the lever on the back of the park brake release handle (6). 4. Lift the park brake release handle to access and snap the plastic retainer clip that secures the park brake release linkage rod to the lever on the back of the park brake release handle over the linkage rod. 5. Reach under the driver side outboard end of the instrument panel to access and engage the park brake release linkage rod end to the park brake mechanism. 6. Snap the plastic retainer clip that secures the park brake release linkage rod to the park brake mechanism on the left cowl side inner panel over the linkage rod. 7. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Parking Brake Shoes Parking Brake Shoe: Adjustments Parking Brake Shoes PARKING BRAKE SHOES CAUTION: Before adjusting the park brake shoes be sure that the park brake pedal is in the fully released position. If park brake pedal is not in the fully released position, the park brake shoes can not be accurately adjusted. 1. Raise vehicle. 2. Remove tire and wheel. 3. Remove disc brake caliper from caliper adapter. 4. Remove rotor from the axleshaft. NOTE: When measuring the brake drum diameter, the diameter should be measured in the center of the area in which the park brake shoes contact the surface of the brake drum. 5. Using Brake Shoe Gauge, Special Tool C-3919 (1), or equivalent, accurately measure the inside diameter of the park brake drum portion (2) of the rotor. 6. Using a ruler (2) that reads in 64th of an inch, accurately read the measurement of the inside diameter of the park brake drum from the special tool (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Parking Brake Shoes > Page 11482 7. Reduce the inside diameter measurement of the brake drum that was taken using Special Tool C-3919 (2) by 1/64 of an inch. Reset Gauge, Brake Shoe, Special Tool C-3919 (2) or the equivalent used, so that the outside measurement jaws are set to the reduced measurement. 8. Place Gauge, Brake Shoe, Special Tool C-3919, or equivalent over the park brake shoes. The special tool must be located diagonally across at the top of one shoe and bottom of opposite shoe (widest point) of the park brake shoes. 9. Using the star wheel adjuster, adjust the park brake shoes until the lining on the park brake shoes just touches the jaws on the special tool. 10. Repeat step 8 above and measure shoes in both directions. 11. Install brake rotor on the axleshaft. 12. Rotate rotor to verify that the park brake shoes are not dragging on the brake drum. If park brake shoes are dragging, remove rotor and back off star wheel adjuster one notch and recheck for brake shoe drag against drum. Continue with the previous step until brake shoes are not dragging on brake drum. 13. Install disc brake caliper on caliper adapter. 14. Install wheel and tire. 15. Tighten the wheel mounting nuts in the proper sequence until all nuts are torqued to half the specified torque. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.) LD, 197 Nm (145 ft. lbs.) HD SRW, 210 Nm (155 ft. lbs.) HD DRW. 16. Lower vehicle. 17. Apply and release the park brake pedal one time. This will seat and correctly adjust the park brake cables. CAUTION: Before moving vehicle, pump brake pedal several times to ensure the vehicle has a firm enough pedal to stop the vehicle. 18. Road test the vehicle to ensure proper function of the vehicle's brake system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Parking Brake Shoes > Page 11483 Parking Brake Shoe: Adjustments With Adjusting Tool WITH ADJUSTING TOOL Adjustment can be made with a standard brake gauge or with adjusting tool. Adjustment is performed with the complete brake assembly installed on the backing plate. 1. Be sure parking brake lever is fully released. 2. Raise vehicle so rear wheels can be rotated freely. 3. Remove plug from each access hole in brake support plates. 4. Loosen parking brake cable adjustment nut until there is slack in front cable. 5. Insert adjusting tool (4) through support plate access hole (1) and engage tool in teeth of adjusting screw star wheel (2). 6. Rotate adjuster screw star wheel (move tool handle upward) until slight drag can be felt when wheel is rotated. 7. Push and hold adjuster lever away from star wheel with thin screwdriver (3). 8. Back off adjuster screw star wheel until brake drag is eliminated. 9. Repeat adjustment at opposite wheel. Be sure adjustment is equal at both wheels. 10. Install support plate access hole plugs. 11. Adjust parking brake cable and lower vehicle. 12. Depress park brake pedal and make sure park brakes hold the vehicle stationary. 13. Release park brake pedal. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Procedures Parking Brake Shoe: Procedures Cleaning - Rear Drum In Hat Brake CLEANING - REAR DRUM IN HAT BRAKE Clean the individual brake components, including the support plate exterior, with a water dampened cloth or with brake cleaner. Do not use any other cleaning agents. Remove light rust and scale from the brake shoe contact pads on the support plate with fine sandpaper. Inspection - Rear Drum In Hat Brake INSPECTION - REAR DRUM IN HAT BRAKE As a general rule, riveted brake shoes (2) should be replaced when worn to within 0.78 mm (1/32 in.) of the rivet heads. Bonded lining should be replaced when worn to a thickness of 1.6 mm (1/16 in.). Examine the lining contact pattern to determine if the shoes are bent or the drum is tapered. The lining should exhibit contact across its entire width. Shoes (2) exhibiting contact only on one side should be replaced and the drum checked for runout or taper. Inspect the adjuster screw assembly (5). Replace the assembly if the star wheel or threads are damaged, or the components are severely rusted or corroded. Discard the brake springs (3) and retainer components (4) if worn, distorted or collapsed. Also replace the springs if a brake drag condition had occurred. Overheating will distort and weaken the springs. Inspect the brake shoe contact pads on the support plate (1), replace the support plate if any of the pads are worn or rusted through. Also replace the plate (1) if it is bent or distorted. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Procedures > Page 11486 Parking Brake Shoe: Removal and Replacement Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Remove the disc brake caliper. 4. Remove the disc brake rotor. 5. Lockout the parking brake cable (2). 6. Disengage the park brake cable (2) from behind the rotor assembly to allow easier disassembly of the park brake shoes. 7. Remove the axleshaft (1). 8. Disassemble the rear park brake shoes (4). Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Procedures > Page 11487 NOTE: On a new vehicle or after parking brake lining replacement, it is recommended that the parking brake system be conditioned prior to use. This is done by making one stop from 25 mph on dry pavement or concrete using light to moderate force on the parking brake foot pedal. 1. Reassemble the rear park brake shoes (1) or. 2. Install the axleshaft (1). 3. Install the park brake cable to the lever behind the support plate. 4. Unlock the park brake cable. 5. Install the disc brake rotor. 6. Install the disc brake caliper. 7. Adjust the rear brake shoes. 8. Install the tire and wheel assembly. 9. Lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Component ID: 474 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : GRAY # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 11491 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 11492 Parking Brake Warning Switch: Diagrams Component ID: 474 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : GRAY # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 11493 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Description and Operation > Description Parking Brake Warning Switch: Description and Operation Description DESCRIPTION The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Description and Operation > Description > Page 11496 Parking Brake Warning Switch: Description and Operation Operation OPERATION The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Description and Operation > Page 11497 Parking Brake Warning Switch: Testing and Inspection PARK BRAKE SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: If the brake indicator stays ON with the ignition switch in the ON position and the park brake released, or comes ON while driving, the brake system must be diagnosed and repaired prior to performing the following tests. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an ineffective park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to STEP 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OKAY 3. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to STEP 2. If not OK, replace the ineffective park brake switch. 4. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Service and Repair > Removal Parking Brake Warning Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Service and Repair > Removal > Page 11500 Parking Brake Warning Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Reach under the left end of the instrument panel to position the park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 Nm (24 in. lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. 5. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Testing and Inspection Hydraulic Brake Booster: Testing and Inspection HYDRAULIC BOOSTER The hydraulic booster uses hydraulic pressure from the power steering pump. Before diagnosing a booster problem, first verify the power steering pump is operating properly. Perform the following checks. - Check the power steering fluid level. - Check the brake fluid level. - Check all power steering hoses and lines for leaks and restrictions. - Check power steering pump pressure. NOISES The hydraulic booster unit will produce certain characteristic booster noises. The noises may occur when the brake pedal is used in a manner not associated with normal braking or driving habits. HISSING A hissing noise may be noticed when above normal brake pedal pressure is applied, 40 lbs. or above. The noise will be more noticeable if the vehicle is not moving. The noise will increase with the brake pedal pressure and an increase of system operating temperature. CLUNK-CHATTER-CLICKING A clunk-chatter-clicking may be noticed when the brake pedal is released quickly, after above normal brake pedal pressure is applied 50-100 lbs.. BOOSTER FUNCTION TEST With the engine off depress the brake pedal several times to discharge the accumulator. Then depress the brake pedal using 40 lbs. of force and start the engine. The brake pedal should fall and then push back against your foot. This indicates the booster is operating properly. ACCUMULATOR LEAKDOWN 1. Start the engine, apply the brakes and turn the steering wheel from lock to lock. This will ensure the accumulator is charged. Turn off the engine and let the vehicle sit for one hour. After one hour there should be at least two power assisted brake application with the engine off. If the system does not retain a charge the booster must be replaced. 2. With the engine off depress the brake pedal several times to discharge the accumulator. Grasp the accumulator and see if it wobbles or turns. If it does the accumulator has lost a gas charge and the booster must be replaced. SEAL LEAKAGE If the booster leaks from any of the seals the booster assembly must be replaced. - INPUT ROD SEAL (3): Fluid leakage from rear end of the booster. - PISTON SEAL (6): Fluid leakage from vent at front of booster. - HOUSING SEAL (4): Fluid leakage between housing and housing cover. - SPOOL VALVE SEAL (7): Fluid leakage near spool plug. - RETURN PORT FITTING SEAL (8): Fluid leakage from port fitting. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Testing and Inspection > Page 11505 Hydraulic Booster Diagnosis Chart Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Procedures Hydraulic Brake Booster: Procedures BLEEDING The hydraulic booster is generally self-bleeding, this procedure will normally bleed the air from the booster. Normal driving and operation of the unit will remove any remaining trapped air. 1. Fill power steering pump reservoir. 2. Disconnect fuel shutdown relay and crank the engine for several seconds, Refer to Fuel System for relay location and WARNING. 3. Check fluid level and add if necessary. 4. Connect fuel shutdown relay and start the engine. 5. Turn the steering wheel slowly from lock to lock twice. 6. Stop the engine and discharge the accumulator by depressing the brake pedal 5 times. 7. Start the engine and turn the steering wheel slowly from lock to lock twice. 8. Turn off the engine and check fluid level and add if necessary. NOTE: If fluid foaming occurs, wait for foam to dissipate and repeat steps 7 and 8. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Procedures > Page 11508 Hydraulic Brake Booster: Removal and Replacement Removal REMOVAL NOTE: If the booster is being replaced because the power steering fluid is contaminated, flush the power steering system before replacing the booster. 1. With engine off depress the brake pedal 5 times to discharge the accumulator. 2. Remove brake lines from master cylinder. 3. Remove mounting nuts from the master cylinder. 4. Remove the bracket from the hydraulic booster lines and master cylinder mounting studs. 5. Remove the master cylinder (3). 6. Remove the return hose (4) and the two pressure lines (1&5) from the hydraulic booster (2). 7. Remove the booster push rod clip, washer and rod remove from the brake pedal. 8. Remove the mounting nuts from the hydraulic booster and remove the booster. Installation INSTALLATION 1. Install the hydraulic booster (2) and tighten the mounting nuts to 28 Nm (21 ft. lbs.). 2. Install the booster push rod, washer and clip onto the brake pedal. 3. Install the master cylinder (3) on the mounting studs. and tighten the mounting nuts to 23 Nm (17 ft. lbs.). 4. Install the brake lines to the master cylinder and tighten to 19 Nm (170 in. lbs.). 5. Install the hydraulic booster line bracket onto the master cylinder mounting studs. 6. Install the master cylinder mounting nuts and tighten to 23 Nm (17 ft. lbs.). 7. Install the hydraulic booster pressure lines (1&5) to the bracket and booster. 8. Tighten the pressure lines to 41 Nm (30 ft. lbs.). NOTE: Inspect o-rings on the pressure line fittings to insure they are in good condition before installation. Replace o-rings if necessary. 9. Install the return hose (4) to the booster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Procedures > Page 11509 10. Bleed base brake system. 11. Fill the power steering pump with fluid. CAUTION: MOPAR (MS-9602) ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill. 12. Bleed the hydraulic booster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Description Vacuum Brake Booster: Description and Operation Description DESCRIPTION All models use a tandem diaphragm, power brake booster (3). NOTE: The power brake booster is not a repairable component. The booster must be replaced as an assembly if diagnosis indicates a malfunction has occurred. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Description > Page 11514 Vacuum Brake Booster: Description and Operation Operation OPERATION The booster unit consists of a single housing divided into two by a tandem diaphragm (3). The outer edge of the diaphragm is secured to the housing. A spacer block (2) is located in between the cowl and the booster housing. The booster push rod (1), connects the booster to the brake pedal and master cylinder (4), is attached to the center of the diaphragm. A check valve (5) is used in the booster outlet connected to the engine intake manifold. Power assist is generated by utilizing a combination of vacuum and atmospheric pressure to boost brake assist. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 11515 Vacuum Brake Booster: Testing and Inspection MASTER CYLINDER/POWER BOOSTER 1. Start engine and check booster vacuum hose connections. A hissing noise indicates vacuum leak. Correct any vacuum leak before proceeding. 2. Stop engine and shift transmission into Neutral. 3. Pump brake pedal until all vacuum reserve in booster is depleted. 4. Press and hold brake pedal under light foot pressure. The pedal should hold firm, if the pedal falls away master cylinder is faulty (internal leakage). 5. Start engine and note pedal action. It should fall away slightly under light foot pressure then hold firm. If no pedal action is discernible, power booster, vacuum supply, or vacuum check valve is faulty. Proceed to the POWER BOOSTER VACUUM TEST. 6. If the POWER BOOSTER VACUUM TEST passes, rebuild booster vacuum reserve as follows: Release brake pedal. Increase engine speed to 1500 rpm, close the throttle and immediately turn off ignition to stop engine. 7. Wait a minimum of 90 seconds and try brake action again. Booster should provide two or more vacuum assisted pedal applications. If vacuum assist is not provided, booster is faulty. POWER BOOSTER VACUUM TEST 1. Connect vacuum gauge (6) to booster check valve (4) with short length of hose (3) and T-fitting (2). 2. Start and run engine at curb idle speed for one minute. 3. Observe the vacuum supply. If vacuum supply is not adequate, repair vacuum supply. 4. Clamp (1) hose (7) shut between intake vacuum source (5) and check valve (4). 5. Stop engine and observe vacuum gauge (6). 6. If vacuum drops more than one inch HG (33 millibars) within 15 seconds, booster diaphragm or check valve is faulty. POWER BOOSTER CHECK VALVE TEST 1. Disconnect vacuum hose from check valve (1). 2. Remove check valve (1) and valve seal (2) from booster (3). 3. Use a hand operated vacuum pump for test. 4. Apply 15-20 inches vacuum at large end of check valve. 5. Plug off the small end to prevent vacuum leakage. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 11516 6. Vacuum should hold steady. If gauge on pump indicates vacuum loss, check valve is faulty and should be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal Vacuum Brake Booster: Service and Repair Removal REMOVAL 1. Remove master cylinder. 2. Disconnect vacuum line at booster. 3. Remove clip securing booster push rod to brake pedal. 4. Remove the nuts (1) from the booster mounting studs. 5. Remove the booster (2) and gasket from front cowl panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal > Page 11519 Vacuum Brake Booster: Service and Repair Installation INSTALLATION 1. Guide the booster (2) studs into the cowl panel holes and seat the booster on the panel. 2. Install and tighten new booster attaching nuts (1) to 28 Nm (250 in. lbs.). 3. Install the booster push rod on brake pedal and install clip. 4. Install the booster check valve if removed and connect the vacuum hose to the check valve. 5. Install the master cylinder. 6. Fill and bleed the brake system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Locations Trailer Brake Control Module: Locations Component ID: 201 Component : MODULE-BRAKE PROVISION Connector: Name : MODULE-BRAKE PROVISION Color : BLUE # of pins : 4 Pin Description Circuit 1 GROUND Z998 18BK 2 BRAKE LAMP SWITCH OUTPUT L50 18WT/TN 3 TRAILER TOW BRAKE B(+) B40 14DG 4 FUSED B(+) A400 14TN/RD Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Locations > Page 11524 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Locations > Page 11525 Trailer Brake Control Module: Diagrams Component ID: 201 Component : MODULE-BRAKE PROVISION Connector: Name : MODULE-BRAKE PROVISION Color : BLUE # of pins : 4 Pin Description Circuit 1 GROUND Z998 18BK 2 BRAKE LAMP SWITCH OUTPUT L50 18WT/TN 3 TRAILER TOW BRAKE B(+) B40 14DG 4 FUSED B(+) A400 14TN/RD Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Locations > Page 11526 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Component ID: 199 Component : MODULE-ANTI-LOCK BRAKES Connector: Name : MODULE-ANTI-LOCK BRAKES Color : # of pins : 46 Qualifier : (AWAL) Pin Description Circuit 1-2 FUSED B(+) A111 16DG/RD 3 CAN C BUS (+) D65 20WT/LG 4-5-6 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT 7-8-9-10 - 11 - 12 LEFT FRONT WHEEL SPEED SENSOR (+) B9 20DG/LG 13 LEFT FRONT WHEEL SPEED SENSOR (-) B8 20DG/TN 14 - 15 - 16 GROUND Z107 16BK/DG 17 - 18 CAN C BUS (-) D64 20WT/LB 19 - 20 - 21 - 22 - 23 - 24 - 25 - 26 RIGHT FRONT WHEEL SPEED SENSOR (+) B7 20DG/VT 27 RIGHT FRONT WHEEL SPEED SENSOR (-) B6 20DG/WT 28 - 29 - 30 - 31 FUSED B(+) A107 12TN/RD 32 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 33 - 34 - - Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 11531 35 - 36 - 37 - 38 - 39 - 40 - 41 REAR WHEEL SPEED SENSOR (-) B22 20DG/YL 42 REAR WHEEL SPEED SENSOR (+) B222 20DG/WT 43 - 44 - 45 GROUND Z127 12BK/DG 46 - Component Location - 32 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 11532 Connector: Name : MODULE-ANTI-LOCK BRAKES Color : BLACK # of pins : 14 Qualifier : (RWAL) Pin Description Circuit 1 REAR WHEEL SPEED SENSOR (+) B222 18DG/WT 2 CAN C BUS (+) D65 18WT/LG 3 CAN C BUS (-) D64 18WT/LB 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 11533 5 LEFT FRONT WHEEL SPEED SENSOR (+) B9 18DG/LG 6 GROUND Z107 16BK/DG 7 FUSED B(+) A111 16DG/RD 8 REAR WHEEL SPEED SENSOR (-) B22 18DG/YL 9 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 10 LEFT FRONT WHEEL SPEED SENSOR (-) B8 18DG/TN 11 - 12 - 13 - 14 - Component Location - 32 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 11534 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 11535 Electronic Brake Control Module: Diagrams Component ID: 199 Component : MODULE-ANTI-LOCK BRAKES Connector: Name : MODULE-ANTI-LOCK BRAKES Color : # of pins : 46 Qualifier : (AWAL) Pin Description Circuit 1-2 FUSED B(+) A111 16DG/RD 3 CAN C BUS (+) D65 20WT/LG 4-5-6 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT 7-8-9-10 - 11 - 12 LEFT FRONT WHEEL SPEED SENSOR (+) B9 20DG/LG 13 LEFT FRONT WHEEL SPEED SENSOR (-) B8 20DG/TN 14 - 15 - 16 GROUND Z107 16BK/DG 17 - 18 CAN C BUS (-) D64 20WT/LB 19 - 20 - 21 - 22 - 23 - 24 - 25 - 26 RIGHT FRONT WHEEL SPEED SENSOR (+) B7 20DG/VT 27 RIGHT FRONT WHEEL SPEED SENSOR (-) B6 20DG/WT 28 - 29 - 30 - 31 FUSED B(+) A107 12TN/RD 32 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 33 - 34 - - Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 11536 35 - 36 - 37 - 38 - 39 - 40 - 41 REAR WHEEL SPEED SENSOR (-) B22 20DG/YL 42 REAR WHEEL SPEED SENSOR (+) B222 20DG/WT 43 - 44 - 45 GROUND Z127 12BK/DG 46 - Component Location - 32 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 11537 Connector: Name : MODULE-ANTI-LOCK BRAKES Color : BLACK # of pins : 14 Qualifier : (RWAL) Pin Description Circuit 1 REAR WHEEL SPEED SENSOR (+) B222 18DG/WT 2 CAN C BUS (+) D65 18WT/LG 3 CAN C BUS (-) D64 18WT/LB 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 11538 5 LEFT FRONT WHEEL SPEED SENSOR (+) B9 18DG/LG 6 GROUND Z107 16BK/DG 7 FUSED B(+) A111 16DG/RD 8 REAR WHEEL SPEED SENSOR (-) B22 18DG/YL 9 BRAKE SWITCH NO. 1 SIGNAL B29 18DG/WT 10 LEFT FRONT WHEEL SPEED SENSOR (-) B8 18DG/TN 11 - 12 - 13 - 14 - Component Location - 32 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 11539 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Description Electronic Brake Control Module: Description and Operation Description DESCRIPTION The Antilock Brake Module (ABM) (2) is mounted to the Hydraulic Control Unit (HCU) (3) and operates the ABS system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Description > Page 11542 Electronic Brake Control Module: Description and Operation Operation OPERATION The ABM voltage source is through the ignition switch in the RUN position. The ABM contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in a diagnostic program memory and are accessible with the scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. NOTE: If the ABM is being replaced with a new ABM is must be reprogrammed with the use of a scan tool. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal Electronic Brake Control Module: Service and Repair Removal REMOVAL 1. Remove the negative battery cable from the battery. 2. Pull up on the ABM harness connector release and remove connector. 3. Remove the ABM mounting bolts . 4. Remove the pump connector from the ABM. 5. Remove the ABM from the HCU . Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal > Page 11545 Electronic Brake Control Module: Service and Repair Installation INSTALLATION NOTE: If the ABM is being replaced with a new ABM is must be reprogrammed with the use of a scan tool. 1. Install ABM to the HCU. 2. Install the pump connector to the ABM. 3. Install mounting bolts. Tighten to 2 Nm (16 in. lbs.). 4. Install the wiring harness connector to the ABM and push down on the release to secure the connector. 5. Install negative battery cable to the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations Trailer Brake Control Module: Locations Component ID: 201 Component : MODULE-BRAKE PROVISION Connector: Name : MODULE-BRAKE PROVISION Color : BLUE # of pins : 4 Pin Description Circuit 1 GROUND Z998 18BK 2 BRAKE LAMP SWITCH OUTPUT L50 18WT/TN 3 TRAILER TOW BRAKE B(+) B40 14DG 4 FUSED B(+) A400 14TN/RD Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations > Page 11549 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations > Page 11550 Trailer Brake Control Module: Diagrams Component ID: 201 Component : MODULE-BRAKE PROVISION Connector: Name : MODULE-BRAKE PROVISION Color : BLUE # of pins : 4 Pin Description Circuit 1 GROUND Z998 18BK 2 BRAKE LAMP SWITCH OUTPUT L50 18WT/TN 3 TRAILER TOW BRAKE B(+) B40 14DG 4 FUSED B(+) A400 14TN/RD Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations > Page 11551 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Component ID: 389 Component : SENSOR-BRAKE FLUID LEVEL Connector: Name : SENSOR-BRAKE FLUID LEVEL Color : BLACK # of pins : 2 Pin Description Circuit 1 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/OR 2 GROUND Z420 20BK/OR Component Location - 32 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 11556 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 11557 Brake Fluid Level Sensor/Switch: Diagrams Component ID: 389 Component : SENSOR-BRAKE FLUID LEVEL Connector: Name : SENSOR-BRAKE FLUID LEVEL Color : BLACK # of pins : 2 Pin Description Circuit 1 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/OR 2 GROUND Z420 20BK/OR Component Location - 32 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 11558 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations Lateral Accelerometer: Locations Component ID: 393 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : # of pins : 6 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/GY 3 DYNAMICS SENSOR LOW DATA LINK D464 20WT/OR 4-5-6 GROUND Z608 20BK/LG Component Location - 52 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 11562 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 11563 Lateral Accelerometer: Diagrams Component ID: 393 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : # of pins : 6 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/GY 3 DYNAMICS SENSOR LOW DATA LINK D464 20WT/OR 4-5-6 GROUND Z608 20BK/LG Component Location - 52 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 11564 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 11565 Lateral Accelerometer: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor. The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Removal Lateral Accelerometer: Service and Repair Removal REMOVAL 1. Remove the center bezel lower trim panel. 2. Remove the cup holder. 3. Disconnect the electrical connector (3) for the dynamics sensor (2). 4. Remove the 3 mounting nuts (1) for the sensor (2). 5. Remove the sensor (2) from the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Removal > Page 11568 Lateral Accelerometer: Service and Repair Installation INSTALLATION 1. Install the dynamics sensor on the mounting studs (2). 2. Install the mounting nuts (1) Tighten to 24 Nm (200 in. lbs.). 3. Reconnect the electrical connector (3). 4. Install the cup holder. 5. Install the center bezel lower trim panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Component ID: 474 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : GRAY # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 11572 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 11573 Parking Brake Warning Switch: Diagrams Component ID: 474 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : GRAY # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 11574 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Description Parking Brake Warning Switch: Description and Operation Description DESCRIPTION The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Description > Page 11577 Parking Brake Warning Switch: Description and Operation Operation OPERATION The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Page 11578 Parking Brake Warning Switch: Testing and Inspection PARK BRAKE SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: If the brake indicator stays ON with the ignition switch in the ON position and the park brake released, or comes ON while driving, the brake system must be diagnosed and repaired prior to performing the following tests. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an ineffective park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to STEP 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OKAY 3. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to STEP 2. If not OK, replace the ineffective park brake switch. 4. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair > Removal Parking Brake Warning Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair > Removal > Page 11581 Parking Brake Warning Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Reach under the left end of the instrument panel to position the park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 Nm (24 in. lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. 5. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set Steering Angle Sensor: Customer Interest ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set NUMBER: 08-044-06 GROUP: Electrical DATE: October 07, 2006 SUBJECT: DTC C1240 - Steering Angle Sensor Over Travel Performance OVERVIEW: This bulletin involves the diagnosis and possible replacement of the Steering Angle Sensor. MODELS: 2007 (DR) Ram Truck NOTE: This bulletin applies to vehicle equipped with the Electronic Stability Program (sales code BNB) and built prior to October 03, 2006 (MDH 1003XX). SYMPTOM/CONDITION: The customer may experience an illumination on the instrument cluster of the "ABS" (Anti-Lock Brake System) and/or the "ESP / BAS" (Electronic Stability Program / Brake Assist System) Warning Lights. Investigation may reveal the presence of Diagnostic Trouble Code (DTC) C1240 Steering Angle Sensor Over Travel Performance (SAS). DIAGNOSIS: 1. Perform the diagnostic test procedure for DTC C1240. This diagnostic procedure can be found on TechCONNECT: select the SERVICE INFO tab > 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 340/445E5P AWAL > DIAGNOSIS and TESTING > C1240 - Steering Angle Sensor Over Travel Performance (SAS). 2. If the diagnostic test procedure for DTC C1240 determines that the Steering Angle Sensor is at fault, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Before starting this procedure, be certain that the front wheels are in the straight-ahead position. 1. Replace the steering column clockspring. Refer to TechCONNECT for detailed service procedures: select the SERVICE INFO tab > 8 - ELECTRICAL > RESTRAINTS > CLOCKSPRING > REMOVAL and INSTALLATION. 2. Clear offsets by initializing the ABS ECU using StarSCAN. 3. Perform the ABS VERIFICATION TEST. This test can be found in: 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 3401445E5P AWAL > STANDARD PROCEDURE > ABS VERIFICATION TEST. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set > Page 11590 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set Steering Angle Sensor: All Technical Service Bulletins ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set NUMBER: 08-044-06 GROUP: Electrical DATE: October 07, 2006 SUBJECT: DTC C1240 - Steering Angle Sensor Over Travel Performance OVERVIEW: This bulletin involves the diagnosis and possible replacement of the Steering Angle Sensor. MODELS: 2007 (DR) Ram Truck NOTE: This bulletin applies to vehicle equipped with the Electronic Stability Program (sales code BNB) and built prior to October 03, 2006 (MDH 1003XX). SYMPTOM/CONDITION: The customer may experience an illumination on the instrument cluster of the "ABS" (Anti-Lock Brake System) and/or the "ESP / BAS" (Electronic Stability Program / Brake Assist System) Warning Lights. Investigation may reveal the presence of Diagnostic Trouble Code (DTC) C1240 Steering Angle Sensor Over Travel Performance (SAS). DIAGNOSIS: 1. Perform the diagnostic test procedure for DTC C1240. This diagnostic procedure can be found on TechCONNECT: select the SERVICE INFO tab > 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 340/445E5P AWAL > DIAGNOSIS and TESTING > C1240 - Steering Angle Sensor Over Travel Performance (SAS). 2. If the diagnostic test procedure for DTC C1240 determines that the Steering Angle Sensor is at fault, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Before starting this procedure, be certain that the front wheels are in the straight-ahead position. 1. Replace the steering column clockspring. Refer to TechCONNECT for detailed service procedures: select the SERVICE INFO tab > 8 - ELECTRICAL > RESTRAINTS > CLOCKSPRING > REMOVAL and INSTALLATION. 2. Clear offsets by initializing the ABS ECU using StarSCAN. 3. Perform the ABS VERIFICATION TEST. This test can be found in: 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 3401445E5P AWAL > STANDARD PROCEDURE > ABS VERIFICATION TEST. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set > Page 11596 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Page 11597 Steering Angle Sensor: Locations Component ID: 425 Component : SENSOR-STEERING ANGLE Connector: Name : SENSOR-STEERING ANGLE Color : BLACK # of pins : 4 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/LG 2 GROUND Z455 20BK/PK 3 CAN C BUS (-) D64 20WT/LB 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Page 11598 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Page 11599 Steering Angle Sensor: Diagrams Component ID: 425 Component : SENSOR-STEERING ANGLE Connector: Name : SENSOR-STEERING ANGLE Color : BLACK # of pins : 4 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/LG 2 GROUND Z455 20BK/PK 3 CAN C BUS (-) D64 20WT/LB 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Technical Service Bulletins > Page 11600 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations Traction Control Switch: Locations Component ID: 463 Component : SWITCH-ESP Connector: Name : SWITCH-ESP Color : # of pins : 6 Pin Description Circuit 1 GROUND Z936 20BK/DG 2 PANEL LAMPS DRIVER E11 20OR/DB 3 ESP ON/OFF SENSE B46 20DG/WT 4 SENSOR GROUND G94 20VT/DB 5-6-Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 11604 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 11605 Traction Control Switch: Diagrams Component ID: 463 Component : SWITCH-ESP Connector: Name : SWITCH-ESP Color : # of pins : 6 Pin Description Circuit 1 GROUND Z936 20BK/DG 2 PANEL LAMPS DRIVER E11 20OR/DB 3 ESP ON/OFF SENSE B46 20DG/WT 4 SENSOR GROUND G94 20VT/DB 5-6-Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 11606 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 11607 Traction Control Switch: Description and Operation DESCRIPTION The ESP switch is located just below the heater and air conditioner controls in the center stack area of the instrument panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Removal Traction Control Switch: Service and Repair Removal REMOVAL 1. Remove the radio trim panel (1). 2. Disconnect the electrical connectors from the radio trim panel. 3. Remove the ESP switch (1) from the switch bank (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Removal > Page 11610 Traction Control Switch: Service and Repair Installation INSTALLATION 1. Install the new switch (1) in the switch bank (2). 2. Reconnect the electrical connectors for the radio trim panel. 3. Install the radio trim panel (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Left Front Component ID: 434 Component : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Color : # of pins : 2 Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR (+) B9 20DG/LG Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR (+) B9 18DG/LG 2 LEFT FRONT WHEEL SPEED SENSOR (-) B8 20DG/TN 2 LEFT FRONT WHEEL SPEED SENSOR (-) B8 18DG/TN Component Location - 38 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 11615 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 11616 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Rear Component ID: 436 Component : SENSOR-WHEEL SPEED-ABS-REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-REAR Color : BLACK # of pins : 2 Qualifier : (EXCEPT ESP) Pin Description Circuit 1 REAR WHEEL SPEED SENSOR (-) B22 18DG/YL 2 REAR WHEEL SPEED SENSOR (+) B222 18DG/WT Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 11617 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 11618 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Left Rear Component ID: 435 Component : SENSOR-WHEEL SPEED-ABS-LEFT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT REAR Color : # of pins : 2 Qualifier : (ESP) Pin Description Circuit 1 REAR WHEEL SPEED SENSOR (-) B3 18DG/YL 2 REAR WHEEL SPEED SENSOR (+) B4 18DG/GY Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 11619 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 11620 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Right Front Component ID: 437 Component : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Color : # of pins : 2 Pin Description Circuit 1 RIGHT FRONT WHEEL SPEED SENSOR (+) B7 20DG/VT 2 RIGHT FRONT WHEEL SPEED SENSOR (-) B6 20DG/WT Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 11621 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 11622 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Right Rear Component ID: 438 Component : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Color : # of pins : 2 Qualifier : (ESP) Pin Description Circuit 1 RIGHT REAR WHEEL SPEED SENSOR (-) B1 18DG/OR 2 RIGHT REAR WHEEL SPEED SENSOR (+) B2 18DG/LB Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 11623 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Left Front Component ID: 434 Component : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Color : # of pins : 2 Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR (+) B9 20DG/LG Pin Description Circuit 1 LEFT FRONT WHEEL SPEED SENSOR (+) B9 18DG/LG 2 LEFT FRONT WHEEL SPEED SENSOR (-) B8 20DG/TN 2 LEFT FRONT WHEEL SPEED SENSOR (-) B8 18DG/TN Component Location - 38 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 11626 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 11627 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Rear Component ID: 436 Component : SENSOR-WHEEL SPEED-ABS-REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-REAR Color : BLACK # of pins : 2 Qualifier : (EXCEPT ESP) Pin Description Circuit 1 REAR WHEEL SPEED SENSOR (-) B22 18DG/YL 2 REAR WHEEL SPEED SENSOR (+) B222 18DG/WT Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 11628 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 11629 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Left Rear Component ID: 435 Component : SENSOR-WHEEL SPEED-ABS-LEFT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT REAR Color : # of pins : 2 Qualifier : (ESP) Pin Description Circuit 1 REAR WHEEL SPEED SENSOR (-) B3 18DG/YL 2 REAR WHEEL SPEED SENSOR (+) B4 18DG/GY Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 11630 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 11631 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Right Front Component ID: 437 Component : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Color : # of pins : 2 Pin Description Circuit 1 RIGHT FRONT WHEEL SPEED SENSOR (+) B7 20DG/VT 2 RIGHT FRONT WHEEL SPEED SENSOR (-) B6 20DG/WT Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 11632 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 11633 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Right Rear Component ID: 438 Component : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Color : # of pins : 2 Qualifier : (ESP) Pin Description Circuit 1 RIGHT REAR WHEEL SPEED SENSOR (-) B1 18DG/OR 2 RIGHT REAR WHEEL SPEED SENSOR (+) B2 18DG/LB Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 11634 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Description Wheel Speed Sensor: Description and Operation Description DESCRIPTION The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front hub/bearings. The third sensor is mounted on top of the rear axle differential housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Description > Page 11637 Wheel Speed Sensor: Description and Operation Operation OPERATION The Wheel Speed Sensor consists of a magnet (1) surrounded by windings from a single strand of wire (5). The sensor sends a small AC signal to the ABM. This signal is generated by magnetic induction. The magnetic induction is created when a toothed sensor ring (exciter ring or tone wheel) (4) passes the stationary magnetic WSS. When the ring gear is rotated, the exciter ring (4) passes the tip of the WSS. As the exciter ring tooth approaches the tip of the WSS, the magnetic lines of force expand, causing the magnetic field to cut across the sensor's windings (5). This, in turn causes current to flow through the WSS circuit in one direction. When the exciter ring tooth moves away from the sensor tip, the magnetic lines of force collapse cutting the winding in the opposite direction. This causes the current to flow in the opposite direction. Every time a tooth of the exciter ring passes the tip of the WSS, an AC signal is generated current. Each AC signal (positive to negative signal or squarewave) is interpreted by the ABM. It then compares the frequency of the sinewave to a time value to calculate vehicle speed. The ABM continues to monitor the frequency to determine a deceleration rate that would indicate a possible wheel-locking tendency. The signal strength of any magnetic induction sensor is directly affected by: - Magnetic field strength; the stronger the magnetic field, the stronger the signal - Number of windings in the sensor; more windings provide a stronger signal - Exciter ring speed; the faster the exciter ring/tone wheel rotates, the stronger the signal will be - Distance (3) "air gap" between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring/tone wheel, the stronger the signal will be. The WSS is not adjustable. A clearance specification has been established for manufacturing tolerances. If the clearance is not within these specifications, then either the WSS or other components may be damaged. The clearance between the WSS and the exciter ring is 0.005 0.050 in. The assembly plant performs a "Rolls Test" on every vehicle that leaves the assembly plant. One of the test performed is a test of the WSS. To properly test the sensor, the assembly plant connects test equipment to the Data Link Connector (DLC). This connector is located to the right of the steering column and attached to the lower portion of the instrument panel. The rolls test terminal is spliced to the WSS circuit. The vehicle is then driven on a set of rollers and the WSS output is monitored for proper operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Page 11638 Wheel Speed Sensor: Testing and Inspection REAR WHEEL ANTILOCK Diagnosis of base brake conditions which are mechanical in nature should be performed first. This includes brake noise, lack of power assist, parking brake, or vehicle vibration during normal braking. The RWAL brake system performs several self-tests every time the ignition switch is turned on and the vehicle is driven. The CAB monitors the system inputs and outputs circuits to verify the system is operating properly. If the CAB senses a malfunction in the system it will set a DTC into memory and trigger the warning lamp. NOTE: A scan tool is used to diagnose the RWAL system. For test procedures refer to the ABS Electrical Diagnostic. See: Antilock Brakes / Traction Control Systems/Testing and Inspection Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor- Wheel Speed-ABS-Front Wheel Speed Sensor: Service and Repair Sensor- Wheel Speed-ABS-Front Removal REMOVAL 1. Remove the front rotor. 2. Remove the wheel speed sensor mounting bolt (1) from the hub (3). 3. Remove the wheel speed sensor (2) from the hub (3). 4. Remove the wiring from the clips and disconnect the electrical connector. Installation INSTALLATION 1. Install the wiring to the clips and Reconnect the electrical connector. 2. Install the wheel speed sensor (2) to the hub (3). 3. Install the wheel speed sensor mounting bolt (1) to the hub (3). Tighten the bolt to 21 Nm (190 in. lbs.). 4. Install the front rotor and brake caliper assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor- Wheel Speed-ABS-Front > Page 11641 Wheel Speed Sensor: Service and Repair Sensor-Wheel Speed-ABS-Rear Removal REMOVAL 1. Raise the vehicle on a hoist. 2. Remove the brake line mounting nut and remove the brake line from the sensor stud. 3. Remove the mounting stud (2) from the sensor and shield. 4. Remove the sensor (1) and shield from the differential housing (3). 5. Disconnect the sensor wire harness and remove the sensor (1). Installation INSTALLATION 1. Connect the harness to the sensor. Be sure the seal is securely in place between the sensor and the wiring connector. 2. Install the O-ring on the sensor (if removed). 3. Insert the sensor (1) in the differential housing (3). 4. Install the sensor shield. 5. Install the sensor mounting stud (2) and tighten to 24 Nm (200 in. lbs.). 6. Install the brake line on the sensor stud (2)and install the nut. 7. Lower the vehicle. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor- Wheel Speed-ABS-Front > Page 11642 1. Raise the vehicle on a hoist. 2. Disconnect the wheel speed sensor electrical connector (3). 3. Remove the mounting bolt (1) from the sensor (4). 4. Remove the sensor (4) from the brake caliper adapter (2). Installation INSTALLATION 1. Insert the wheel speed sensor (4) in the brake caliper adapter (2). 2. Install the sensor mounting bolt (1) and tighten to 24 Nm (200 in. lbs.). 3. Reconnect the electrical wiring connector (3) to the sensor (4). 4. Lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations Yaw Rate Sensor: Locations Component ID: 393 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : # of pins : 6 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/GY 3 DYNAMICS SENSOR LOW DATA LINK D464 20WT/OR 4-5-6 GROUND Z608 20BK/LG Component Location - 52 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 11646 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 11647 Yaw Rate Sensor: Diagrams Component ID: 393 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : # of pins : 6 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 2 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/GY 3 DYNAMICS SENSOR LOW DATA LINK D464 20WT/OR 4-5-6 GROUND Z608 20BK/LG Component Location - 52 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 11648 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 11649 Yaw Rate Sensor: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor. The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Removal Yaw Rate Sensor: Service and Repair Removal REMOVAL 1. Remove the center bezel lower trim panel. 2. Remove the cup holder. 3. Disconnect the electrical connector (3) for the dynamics sensor (2). 4. Remove the 3 mounting nuts (1) for the sensor (2). 5. Remove the sensor (2) from the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Removal > Page 11652 Yaw Rate Sensor: Service and Repair Installation INSTALLATION 1. Install the dynamics sensor on the mounting studs (2). 2. Install the mounting nuts (1) Tighten to 24 Nm (200 in. lbs.). 3. Reconnect the electrical connector (3). 4. Install the cup holder. 5. Install the center bezel lower trim panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Component ID: 388 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 BATT TEMP SIGNAL K25 20DB/VT 2 SENSOR GROUND K900 20DB/DG Component Location - 32 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 11658 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 11659 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 11660 Battery Temperature Sensor: Diagrams Component ID: 388 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 BATT TEMP SIGNAL K25 20DB/VT 2 SENSOR GROUND K900 20DB/DG Component Location - 32 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 11661 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 11662 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Description DESCRIPTION The Battery Temperature Sensor (BTS) is used only on the diesel engine. It is attached to the battery tray located under the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description > Page 11665 Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Operation OPERATION The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Removal REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4) . 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3) . 3. Disconnect sensor from engine wire harness electrical connector. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal > Page 11668 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Installation INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal Ignition Switch Lock Cylinder: Service and Repair Removal REMOVAL The ignition key must be in the key cylinder (1) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at the underside of the key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal > Page 11674 Ignition Switch Lock Cylinder: Service and Repair Installation INSTALLATION The ignition key must be in the key cylinder (3) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (3) with the ignition switch (1). 2. Push the key cylinder (3) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Switch-Clutch Interlock Neutral Safety Switch: Locations Switch-Clutch Interlock Component ID: 459 Component : SWITCH-CLUTCH INTERLOCK Connector: Name : SWITCH-CLUTCH INTERLOCK Color : GREEN # of pins : 2 Qualifier : (M/T) Pin Description Circuit 1 TRS T41 SIGNAL (P/N) T41 20YL/DB 2 GROUND Z911 20BK Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Switch-Clutch Interlock > Page 11679 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Switch-Clutch Interlock > Page 11680 Neutral Safety Switch: Locations Switch-Clutch Interlock/Upstop Component ID: 460 Component : SWITCH-CLUTCH INTERLOCK/UPSTOP Connector: Name : SWITCH-CLUTCH INTERLOCK/UPSTOP Color : # of pins : 6 Qualifier : (6.7L) Pin Description Circuit 1-2-3 CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT T26 18DG/OR 4 GROUND Z993 18BK 5-6-- Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Switch-Clutch Interlock > Page 11681 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Switch-Clutch Interlock Neutral Safety Switch: Diagrams Switch-Clutch Interlock Component ID: 459 Component : SWITCH-CLUTCH INTERLOCK Connector: Name : SWITCH-CLUTCH INTERLOCK Color : GREEN # of pins : 2 Qualifier : (M/T) Pin Description Circuit 1 TRS T41 SIGNAL (P/N) T41 20YL/DB 2 GROUND Z911 20BK Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Switch-Clutch Interlock > Page 11684 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Switch-Clutch Interlock > Page 11685 Neutral Safety Switch: Diagrams Switch-Clutch Interlock/Upstop Component ID: 460 Component : SWITCH-CLUTCH INTERLOCK/UPSTOP Connector: Name : SWITCH-CLUTCH INTERLOCK/UPSTOP Color : # of pins : 6 Qualifier : (6.7L) Pin Description Circuit 1-2-3 CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT T26 18DG/OR 4 GROUND Z993 18BK 5-6-- Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Switch-Clutch Interlock > Page 11686 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams Relay - Starter Motor (Except SRT) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Battery Cables - Description Battery Cable: Description and Operation Battery Cables - Description DESCRIPTION The battery cables (1) and (3) are large gauge, stranded copper wires sheathed within a heavy plastic or synthetic rubber insulating jacket. The wire used in the battery cables combines excellent flexibility and reliability with high electrical current carrying capacity. The battery cables feature a stamped brass clamping type female battery terminal crimped onto one end of the battery cable wire and then solder-dipped. A square headed pinch-bolt and hex nut are installed at the open end of the female battery terminal clamp. Large eyelet type terminals are crimped onto the opposite end of the battery cable wire and then solder-dipped. The battery positive cable wires (1) have a red insulating jacket to provide visual identification and feature a larger female battery terminal clamp to allow connection to the larger battery positive terminal post. The battery negative cable wires (3) have a black insulating jacket and a smaller female battery terminal clamp. The battery cables cannot be repaired and, if damaged or inoperative they must be replaced. Both the battery positive and negative cables are available for service replacement. Refer to the appropriate wiring information for the location of the proper battery cable wire harness diagrams. The wiring information also includes proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Battery Cables - Description > Page 11696 Battery Cable: Description and Operation Battery Cables - Operation OPERATION The battery cables connect the battery terminal posts to the vehicle electrical system. These cables also provide a path back to the battery for electrical current generated by the charging system for restoring the voltage potential of the battery. The female battery terminal clamps on the ends of the battery cable wires provide a strong and reliable connection of the battery cable to the battery terminal posts. The terminal pinch bolts allow the female terminal clamps to be tightened around the male terminal posts on the top of the battery. The eyelet terminals secured to the opposite ends of the battery cable wires provide secure and reliable connection of the battery cables to the vehicle electrical system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 11697 Battery Cable: Testing and Inspection BATTERY CABLES A voltage drop test will determine if there is excessive resistance in the battery cable terminal connections or the battery cables. If excessive resistance is found in the battery cable connections, the connection point should be disassembled, cleaned of all corrosion or foreign material, then reassembled. Following reassembly, check the voltage drop for the battery cable connection and the battery cable again to confirm repair. When performing the voltage drop test, it is important to remember that the voltage drop is giving an indication of the resistance between the two points at which the voltmeter probes are attached. EXAMPLE: When testing the resistance of the battery positive cable, touch the voltmeter leads to the battery positive cable terminal clamp and to the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud. If you probe the battery positive terminal post and the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud, you are reading the combined voltage drop in the battery positive cable terminal clamp-to-terminal post connection and the battery positive cable. VOLTAGE DROP TEST WARNING: Models equipped with a diesel engine have an automatic shutdown (asd) relay located in the power distribution center (PDC). Removal of the asd relay may not prevent the diesel engine from starting. Be certain to disconnect the fuel shutdown solenoid wire harness connector to prevent the engine from starting. Failure to do so may result in personal injury. The following operation will require a voltmeter accurate to 1/10 (0.10) volt. Before performing this test, be certain that the following procedures are accomplished: - The battery is fully-charged and tested. - Fully engage the parking brake. - If the vehicle is equipped with an automatic transmission, place the gearshift selector lever in the Park position. If the vehicle is equipped with a manual transmission, place the gearshift selector lever in the Neutral position and block the clutch pedal in the fully depressed position. - Verify that all lamps and accessories are turned off. 1. Connect the positive lead of the voltmeter (1) to the battery negative terminal post. Connect the negative lead of the voltmeter to the battery negative cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery negative cable terminal clamp and the battery negative terminal post. NOTE: If the vehicle is equipped with two 12v batteries, step #1 must be performed twice, once for each battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 11698 2. Connect the positive lead of the voltmeter (1) to the battery positive terminal post. Connect the negative lead of the voltmeter to the battery positive cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery positive cable terminal clamp and the battery positive terminal post. NOTE: If the vehicle is equipped with two 12v batteries, step #2 must be performed twice, once for each battery. 3. Connect the voltmeter (2) to measure between the battery positive cable terminal clamp (1) and the starter solenoid (3) B(+) terminal stud. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery positive cable eyelet terminal connection at the starter solenoid B(+) terminal stud. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery positive cable. NOTE: If the vehicle is equipped with two 12v batteries, step #3 must be performed twice, once for each battery. 4. Connect the voltmeter (1) to measure between the battery (2) negative cable terminal clamp and a good clean ground on the engine block (3). Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery negative cable eyelet terminal connection to the engine block. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery negative cable. NOTE: If the vehicle is equipped with two 12v batteries, step #4 must be performed twice, once for each battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal Battery Cable: Service and Repair Battery Cables - Removal REMOVAL NEGATIVE - GASOLINE ENGINE 1. Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off. 2. Disconnect and isolate the battery negative cable terminal clamp (3). 3. Remove the bolt (4) securing the negative cable to the left front fender. 4. One at a time, trace the battery cable retaining pushpins (3) , fasteners and routing clips until the cable is free from the vehicle. 5. Remove the bolt (4) securing the negative cable to the engine. 6. Remove the bolt (6) securing the negative cable to the left frame rail. 7. Remove the battery negative cable from the vehicle. POSITIVE - GASOLINE ENGINE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 11701 1. Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off. 2. Disconnect and isolate the battery negative cable terminal clamp (3). 3. Disconnect the battery positive cable terminal clamp (1). 4. Remove the nut (9) securing the cable to the Totally Integrated Power Module (TIPM) (5). 5. Disconnect the wire harness connector (6) at the TIPM. 6. Disconnect the wire harness connector (7) pushpin from the TIPM housing. 7. Disconnect the battery cable retaining pushpin (8) securing the cable to the battery tray. 8. Raise the vehicle on a hoist. 9. Disconnect the battery cable retaining pushpins (1) securing the cable to the left frame rail. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 11702 10. Remove the nut (5) securing the cable to the starter solenoid (6). 11. Lower the vehicle. 12. Lift the terminal cap (4) and remove the nut (3) securing the cable (1) to the alternator (2). 13. Disconnect any remaining pushpins securing the cable to the vehicle. 14. Remove the battery positive cable from the vehicle. NEGATIVE - DIESEL ENGINE - LEFT 1. Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off. 2. Disconnect and isolate the battery negative cable terminal clamps (1 and 9). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 11703 3. Remove the bolt (4) securing the negative cable to the left front fender. 4. Remove the bolt (6) securing the negative cable (2) to the engine. 5. Remove the bolt (7) securing the negative cable (2) to the left frame rail (1). 6. One at a time, trace the battery cable retaining pushpins, fasteners and routing clips until the cable is free from the vehicle. 7. Remove the battery negative cable from the vehicle. NEGATIVE - DIESEL ENGINE - RIGHT 1. Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 11704 2. Disconnect and isolate the battery negative cable terminal clamps (1 and 9). 3. Remove the bolt (2) securing the negative cable (3) to the right front fender. 4. Remove the bolt (4) securing the negative cable (5) to the engine (6). 5. One at a time, trace the battery cable retaining pushpins, fasteners and routing clips until the cable is free from the vehicle. 6. Remove the battery negative cable from the vehicle. POSITIVE - DIESEL ENGINE - LEFT 1. Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off. 2. Disconnect and isolate the battery negative cable terminal clamps (1 and 9). 3. Remove the nut (8) securing the right battery positive cable terminal (6) to the left battery positive cable terminal clamp (5). 4. Remove the right cable terminal from the left cable terminal clamp. 5. Disconnect the battery positive cable terminal clamp (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 11705 6. Raise the vehicle on a hoist. 7. Remove the stud bolt (3) securing the cable to the engine. 8. Lift the terminal cover (4) and remove the nut securing the cable to the starter solenoid (5). 9. Lower the vehicle. 10. One at a time, trace the battery cable retaining pushpins, fasteners and routing clips until the cable is free from the vehicle. 11. Remove the battery positive cable from the vehicle. POSITIVE - DIESEL ENGINE - RIGHT 1. Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off. 2. Disconnect and isolate the battery negative cable terminal clamps (1 and 9). 3. Remove the nut (8) securing the right battery positive cable terminal (6) to the left battery positive cable terminal clamp (5). 4. Remove the right cable terminal from the left cable terminal clamp. 5. Remove the battery cable fastener clips (11) to free the cable from the vehicle. 6. Disconnect the right battery positive cable terminal clamp (13). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 11706 7. Lift the terminal cover (1) and remove the nut (7) securing the cable (2) to the alternator (3). 8. One at a time, trace the battery cable retaining pushpins, fasteners and routing clips until the cable is free from the vehicle. 9. Remove the battery positive cable from the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 11707 Battery Cable: Service and Repair Battery Cables - Installation INSTALLATION NEGATIVE - GASOLINE ENGINE 1. Position the battery negative cable (5) in the vehicle. 2. One at a time, install the battery cable retaining pushpins (3) , fasteners and routing clips until the cable is secure in the vehicle. 3. Install the bolt (6) securing the negative cable (1) to the left frame rail. 4. Install the bolt (4) securing the negative cable (5) to the engine. 5. Install the bolt (4) securing the negative cable (3) to the left front fender. 6. Connect the battery negative cable terminal clamp (3). 7. Check the vehicle for normal operation. POSITIVE - GASOLINE ENGINE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 11708 1. Position the battery positive cable (1) in the vehicle. 2. Install the nut (3) securing the cable (1) to the alternator (2). 3. Secure the terminal cap (4) to the alternator stud. 4. Install the cable (1) pushpin into the bracket to the left of the alternator. 5. Raise the vehicle on a hoist. 6. Install the nut (5) securing the cable to the starter solenoid (6). 7. Connect the battery cable retaining pushpins (1) securing the cable to the left frame rail. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 11709 8. Lower the vehicle. 9. Install the battery cable retaining pushpin (8) securing the cable to the battery tray. 10. Install the wire harness connector (7) pushpin into the Totally Integrated Power Module (TIPM) (5) housing. 11. Connect the wire harness connector (6) at the TIPM. 12. Install the nut (9) securing the cable to the TIPM. 13. Connect the battery positive cable terminal clamp (1). 14. Connect the battery negative cable terminal clamp (3). 15. Check the vehicle for normal operation. NEGATIVE - DIESEL ENGINE - LEFT 1. Position the battery negative cable (2) in the vehicle. 2. One at a time, install the battery cable retaining pushpins, fasteners and routing clips until the cable is secure in the vehicle. 3. Install the bolt (7) securing the negative cable (2) to the left frame rail (1). 4. Install the bolt (6) securing the negative cable (2) to the engine. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 11710 5. Install the bolt (4) securing the negative cable to the left front fender. 6. Connect the battery negative cable terminal clamps (1 and 9). 7. Check the vehicle for normal operation. NEGATIVE - DIESEL ENGINE - RIGHT 1. Position the battery negative cable (3) in the vehicle. 2. One at a time, install the battery cable retaining pushpins, fasteners and routing clips until the cable is secure in the vehicle. 3. Install the bolt (2) securing the negative cable to the right front fender. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 11711 4. Install the bolt (4) securing the negative cable (5) to the engine (6). 5. Connect the battery negative cable terminal clamps (1 and 9). 6. Check the vehicle for normal operation. POSITIVE - DIESEL ENGINE - LEFT 1. Position the battery positive cable (4) in the vehicle. 2. One at a time, install the battery cable retaining pushpins, fasteners and routing clips until the cable is secure in the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 11712 3. Raise the vehicle on a hoist. 4. Install the nut securing the cable to the starter solenoid (5) and secure the terminal cover (4) in place. 5. Install the stud bolt (3) securing the cable to the engine. 6. Lower the vehicle. 7. Install the battery positive cable terminal clamp (5). 8. Install the right battery positive cable terminal (6) onto the left cable terminal clamp (5). 9. Install the nut (8) securing the right cable terminal (6) to the left positive battery cable terminal clamp (5). 10. Connect the battery negative cable terminal clamps (1 and 9). 11. Check the vehicle for normal operation. POSITIVE - DIESEL ENGINE - RIGHT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 11713 1. Position the right battery positive cable (13) in the vehicle. 2. After positioning the cable install the battery cable fastener clips (11) to the vehicle. 3. Install the right battery positive cable terminal (6) to the left battery positive cable terminal clamp (5). 4. Install the nut (8) securing the right cable terminal (6) to the left cable terminal clamp (5). 5. Connect the right battery positive cable terminal clamp (13). 6. Lift the terminal cover (1) and install the nut (7) securing the cable (2) to the alternator (3). Secure the terminal cover to the alternator. 7. Connect the battery negative cable terminal clamps (1 and 9). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 11714 8. Check the vehicle for normal operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Component ID: 388 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 BATT TEMP SIGNAL K25 20DB/VT 2 SENSOR GROUND K900 20DB/DG Component Location - 32 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 11718 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 11719 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 11720 Battery Temperature Sensor: Diagrams Component ID: 388 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Description Circuit 1 BATT TEMP SIGNAL K25 20DB/VT 2 SENSOR GROUND K900 20DB/DG Component Location - 32 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 11721 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 11722 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Description DESCRIPTION The Battery Temperature Sensor (BTS) is used only on the diesel engine. It is attached to the battery tray located under the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description > Page 11725 Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Operation OPERATION The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Removal REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4) . 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3) . 3. Disconnect sensor from engine wire harness electrical connector. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal > Page 11728 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Installation INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Description and Operation Battery Tray: Description and Operation DESCRIPTION The molded plastic battery tray (1) is located in the left front corner of the engine compartment. On this vehicle, the battery tray also provides an anchor point for the anti-lock brake controller (3), cruise control servo (if equipped) and the integrated power module (4). The battery hold down hardware is contained within the battery tray. A hole in the bottom of the battery tray (2) is fitted with a battery temperature sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Retainer - Removal Battery Tray: Service and Repair Battery Retainer - Removal REMOVAL CAUTION: Never operate a vehicle without a battery hold down device properly installed. Damage to the vehicle, components and battery could result. 1. Verify that the ignition switch and all accessories are OFF. 2. Disconnect and isolate the battery negative cable. 3. Remove the bolt (6) from the battery hold down bracket (5) and remove the bracket from the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Retainer - Removal > Page 11734 Battery Tray: Service and Repair Battery Retainer - Installation INSTALLATION 1. Clean and inspect the battery hold down bracket (5) and bolt (6). 2. Position the battery hold down bracket in the battery tray. CAUTION: Be certain that the hold down bracket is properly positioned in the battery tray before tightening the hold down bolt or damage to the battery and tray may result. 3. Install and tighten the battery hold down retaining bolt. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Retainer - Removal > Page 11735 Battery Tray: Service and Repair Battery Tray - Removal REMOVAL LEFT SIDE 1. Remove the battery (3) from the battery tray. 2. Remove the Totally Integrated Power Module (TIPM) (5). 3. Disconnect the wire harness retainers from the battery tray assembly. 4. Disconnect the purge solenoid (6) from its mounting bracket. 5. Remove the anti-lock brake controller (if equipped) retaining bolts and support the brake controller with mechanics wire. It is not necessary to completely remove the anti-lock brake control unit. 6. Remove the left front wheelhouse splash shield. 7. Mark the location of the cruise servo (3) (if equipped) and remove the retaining screws. Position the servo out of the way. 8. Remove the battery temperature sensor from the battery tray. 9. Disconnect the left front fender ground wire. 10. Remove the remaining battery tray retaining bolts (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Retainer - Removal > Page 11736 11. Remove the battery tray from the vehicle. RIGHT SIDE 1. Remove the battery from the battery tray. 2. Remove the right front wheelhouse splash shield. 3. Disconnect the right front fender ground wire. 4. Remove fasteners from grid heater relay bracket. 5. Remove air box. 6. Remove the remaining battery tray retaining bolts. 7. Remove the battery tray from the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Retainer - Removal > Page 11737 Battery Tray: Service and Repair Battery Tray - Installation INSTALLATION LEFT SIDE 1. Position the battery tray assembly (1) and install the retaining bolts (2). 2. Connect the left front fender ground wire. 3. Install the battery temperature sensor in the battery tray. 4. Install the cruise servo (3) (if equipped) and retaining screws. 5. Install the left front wheelhouse splash shield. 6. Install the anti-lock brake controller (if equipped). 7. Install the purge solenoid (6) on its mounting bracket. 8. Connect the wire harness retainers on the battery tray assembly. 9. Install the Totally Integrated Power Module (TIPM) (5). 10. Install the battery (3). RIGHT SIDE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Retainer - Removal > Page 11738 1. Position the battery tray assembly and install the retaining bolts. 2. Connect the right front fender ground wire. 3. Install the air box. 4. Install the grid heater relay bracket. 5. Install the right front wheelhouse splash shield. 6. Install the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Description and Operation > Description Alternator Pulley: Description and Operation Description DESCRIPTION The generator decoupler is used only with certain engines. The decoupler is used in place of the standard generator drive pulley. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Description and Operation > Description > Page 11745 Alternator Pulley: Description and Operation Operation OPERATION The generator decoupler is used only with certain engines. The decoupler is a one-way clutch designed to help reduce belt tension fluctuation, vibration, reduce fatigue loads, improve belt life, reduce hubloads on components, and reduce noise. Dry operation is used (no grease or lubricants). The decoupler is not temperature sensitive and also has a low sensitivity to electrical load. The decoupler is a non-serviceable item and is to be replaced as an assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Service and Repair > Removal Alternator Pulley: Service and Repair Removal REMOVAL The generator decoupler is used only with certain engines. Two different type generator decoupler pulleys are used. One can be identified by the use of machined splines (3) . The other decoupler is equipped with a hex opening (2) and will not use splines. Different special tools are required to service each different decoupler. Refer to following procedure. INA Decoupler 1. Disconnect negative battery cable. 2. Remove generator and accessory drive belt. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Service and Repair > Removal > Page 11748 3. Position Special Tool #8823 (VM.1048) (2) into decoupler (1) . 4. Determine if end of generator shaft is hex shaped (2). 5. ............ or is splined (2) . Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Service and Repair > Removal > Page 11749 6. If hex is used, insert a 10MM deep socket (1) into tool #8823 (VM.1048) . 7. If splined, insert a 5/16 Inch 6-point hex driver (1), or a 10MM 12-point triple square driver into tool #8823 (VM.1048) . 8. The generator shaft uses conventional right-hand threads to attach decoupler. To break decoupler loose from generator threads, rotate end of tool (1) clockwise or..........., Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Service and Repair > Removal > Page 11750 9. rotate end of tool (1) clockwise . 10. After breaking loose with tool, unthread decoupler by hand from generator. Litens Decoupler 1. Disconnect negative battery cable. 2. Remove generator and accessory drive belt. 3. Position Special Tool #8433 into decoupler. Align to hex end of generator shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Service and Repair > Removal > Page 11751 4. The generator shaft uses conventional right-hand threads to attach decoupler. To break decoupler loose from generator threads, rotate end of tool clockwise . 5. After breaking loose with tool, unthread decoupler by hand from generator. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Service and Repair > Removal > Page 11752 Alternator Pulley: Service and Repair Installation INSTALLATION INA Decoupler 1. Thread decoupler pulley onto generator shaft by hand (right-hand threads). 2. Position Special Tool #8823 (VM.1048) into decoupler. 3. Determine if end of generator shaft is hex shaped or is splined. If hex is used, insert a 10MM deep socket (1) into tool #8823 (VM.1048) or.............. 4. ............if splined, insert a 5/16 6-point hex driver (1), or a 10MM 12-point triple square driver into tool #8823 (VM.1048) . 5. Do not use an adjustable, ratcheting "click type" torque wrench. Most "click type" wrenches will only allow torque to be applied in a clockwise rotation. Use a dial-type or beam-type wrench. Tighten in counterclockwise rotation and tighten to 110 Nm (81 ft. lbs.). 6. Install accessory drive belt, and generator. 7. Connect negative battery cable. Litens Decoupler Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Service and Repair > Removal > Page 11753 1. Thread decoupler pulley onto generator shaft by hand (right-hand threads). 2. Position Special Tool 8433 into decoupler. Align tool to hex end of generator shaft. 3. Do not use an adjustable, ratcheting "click type" torque wrench. Most "click type" wrenches will only allow torque to be applied in a clockwise rotation. Use a dial-type or beam-type wrench. Tighten in counterclockwise rotation and tighten to 110 Nm (81 ft. lbs.). 4. Install accessory drive belt, and generator. 5. Connect negative battery cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Description and Operation > Description Voltage Regulator: Description and Operation Description DESCRIPTION The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulating circuit located within the PCM (Powertrain Control Module) (within the ECM for diesel engines). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Description and Operation > Description > Page 11758 Voltage Regulator: Description and Operation Operation OPERATION The amount of direct current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground. Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field. The EVR circuitry monitors system line voltage (B+) and battery temperature (refer to Battery Temperature Sensor). It then determines a target charging voltage. If sensed battery voltage is 0.5 volts or lower than the target voltage, the PCM grounds the field winding until sensed battery voltage is 0.5 volts above target voltage. A circuit in the PCM cycles the ground side of the generator field up to 100 times per second (100Hz), but has the capability to ground the field control wire 100% of the time (full field) to achieve the target voltage. If the charging rate cannot be monitored (limp-in), a duty cycle of 25% is used by the PCM in order to have some generator output. Also refer to Charging System Operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal Ignition Switch Lock Cylinder: Service and Repair Removal REMOVAL The ignition key must be in the key cylinder (1) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at the underside of the key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal > Page 11765 Ignition Switch Lock Cylinder: Service and Repair Installation INSTALLATION The ignition key must be in the key cylinder (3) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (3) with the ignition switch (1). 2. Push the key cylinder (3) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start Antenna > Component Information > Technical Service Bulletins > Remote Start System - Antenna Diagnostic Chart Keyless Start Antenna: Technical Service Bulletins Remote Start System - Antenna Diagnostic Chart NUMBER: 08-003-07 GROUP: Electrical DATE: January 27, 2007 SUBJECT: Remote Start System - Diagnostic Chart For Antenna OVERVIEW: This bulletin involves a diagnostic chart that may be used to aid the technician with the diagnosis of the antenna on an originally equipped (factory installed) remote start system. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2006-2007 (HB/HG) Durango/Aspen 2007 (JS) Sebring/Avenger 2007 (KA) Nitro 2007 (ND) Dakota 2007 (WK) Grand Cherokee 2007 (XK) Commander NOTE: This bulletin applies to vehicles with an original equipment Remote Start system (sales code XBM). DISCUSSION: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start Antenna > Component Information > Technical Service Bulletins > Remote Start System - Antenna Diagnostic Chart > Page 11771 The customer may notice that the signal range of the Remote Keyless Entry (RKE) system is reduced. The RKE key fob may need to be closer than 3 meters (10 feet) before the functions available on the key fob will operate. This condition may be due to the RKE antenna. The diagnostic flow chart is provide as a diagnostic aid for dealer technician (Fig. 1). POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Switch-Clutch Interlock Neutral Safety Switch: Locations Switch-Clutch Interlock Component ID: 459 Component : SWITCH-CLUTCH INTERLOCK Connector: Name : SWITCH-CLUTCH INTERLOCK Color : GREEN # of pins : 2 Qualifier : (M/T) Pin Description Circuit 1 TRS T41 SIGNAL (P/N) T41 20YL/DB 2 GROUND Z911 20BK Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Switch-Clutch Interlock > Page 11776 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Switch-Clutch Interlock > Page 11777 Neutral Safety Switch: Locations Switch-Clutch Interlock/Upstop Component ID: 460 Component : SWITCH-CLUTCH INTERLOCK/UPSTOP Connector: Name : SWITCH-CLUTCH INTERLOCK/UPSTOP Color : # of pins : 6 Qualifier : (6.7L) Pin Description Circuit 1-2-3 CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT T26 18DG/OR 4 GROUND Z993 18BK 5-6-- Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Switch-Clutch Interlock > Page 11778 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Switch-Clutch Interlock Neutral Safety Switch: Diagrams Switch-Clutch Interlock Component ID: 459 Component : SWITCH-CLUTCH INTERLOCK Connector: Name : SWITCH-CLUTCH INTERLOCK Color : GREEN # of pins : 2 Qualifier : (M/T) Pin Description Circuit 1 TRS T41 SIGNAL (P/N) T41 20YL/DB 2 GROUND Z911 20BK Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Switch-Clutch Interlock > Page 11781 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Switch-Clutch Interlock > Page 11782 Neutral Safety Switch: Diagrams Switch-Clutch Interlock/Upstop Component ID: 460 Component : SWITCH-CLUTCH INTERLOCK/UPSTOP Connector: Name : SWITCH-CLUTCH INTERLOCK/UPSTOP Color : # of pins : 6 Qualifier : (6.7L) Pin Description Circuit 1-2-3 CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT T26 18DG/OR 4 GROUND Z993 18BK 5-6-- Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Switch-Clutch Interlock > Page 11783 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations Starter Motor: Locations Component ID: 456 Component : STARTER Connector: Name : STARTER Color : # of pins : 1 Qualifier : (3.7L A/T/4.7L A/T/5.7L) Pin Description Circuit 1 STARTER MOTOR CONTROL OUTPUT T750 14YL/GY Component Location - 36 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 11787 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 11788 Connector: Name : STARTER Color : # of pins : 1 Qualifier : (3.7L M/T/4.7L M/T) Pin Description Circuit 1 STARTER MOTOR CONTROL OUTPUT T750 14YL/GY Component Location - 36 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 11789 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 11790 Connector: Name : STARTER Color : GRAY # of pins : 1 Qualifier : (DIESEL) Pin Description Circuit 1 STARTER MOTOR CONTROL OUTPUT T750 14YL/GY Component Location - 36 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 11791 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 11792 Connector: Name : STARTER-EYELET Color : # of pins : 0 Qualifier : (3.7L/4.7L) Pin Description Circuit 1 B(+) A8 6RD Component Location - 36 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 11793 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 11794 Connector: Name : STARTER-EYELET Color : # of pins : 1 Qualifier : (5.7L) Pin Description Circuit 1 B(+) A8 6RD Component Location - 36 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 11795 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 11796 Connector: Name : STARTER-EYELET Color : # of pins : 1 Qualifier : (DIESEL) Pin Description Circuit 1 B(+) A8 2RD Component Location - 36 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 11797 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 11798 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 11799 Starter Motor: Diagrams Component ID: 456 Component : STARTER Connector: Name : STARTER Color : # of pins : 1 Qualifier : (3.7L A/T/4.7L A/T/5.7L) Pin Description Circuit 1 STARTER MOTOR CONTROL OUTPUT T750 14YL/GY Component Location - 36 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 11800 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 11801 Connector: Name : STARTER Color : # of pins : 1 Qualifier : (3.7L M/T/4.7L M/T) Pin Description Circuit 1 STARTER MOTOR CONTROL OUTPUT T750 14YL/GY Component Location - 36 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 11802 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 11803 Connector: Name : STARTER Color : GRAY # of pins : 1 Qualifier : (DIESEL) Pin Description Circuit 1 STARTER MOTOR CONTROL OUTPUT T750 14YL/GY Component Location - 36 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 11804 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 11805 Connector: Name : STARTER-EYELET Color : # of pins : 0 Qualifier : (3.7L/4.7L) Pin Description Circuit 1 B(+) A8 6RD Component Location - 36 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 11806 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 11807 Connector: Name : STARTER-EYELET Color : # of pins : 1 Qualifier : (5.7L) Pin Description Circuit 1 B(+) A8 6RD Component Location - 36 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 11808 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 11809 Connector: Name : STARTER-EYELET Color : # of pins : 1 Qualifier : (DIESEL) Pin Description Circuit 1 B(+) A8 2RD Component Location - 36 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 11810 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 11811 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 11812 Starter Motor: Testing and Inspection DIAGNOSIS AND TESTING - STARTER MOTOR Correct starter motor operation can be confirmed by performing the following free running bench test. This test can only be performed with starter motor removed from vehicle. Refer to Specifications for starter motor specifications. 1. Remove starter motor from vehicle. 2. Mount starter motor securely in a soft-jawed bench vise. The vise jaws should be clamped on the mounting flange of starter motor. Never clamp on starter motor by field frame. 3. Connect a suitable volt-ampere tester and a 12-volt battery to starter motor in series, and set ammeter to 100 ampere scale. See instructions provided by manufacturer of volt-ampere tester being used. 4. Install jumper wire from solenoid terminal to solenoid battery terminal. The starter motor should operate. If starter motor fails to operate, replace faulty starter motor assembly. 5. Adjust carbon pile load of tester to obtain free running test voltage. Refer to Specifications for starter motor free running test voltage specifications. 6. Note reading on ammeter and compare reading to free running test maximum amperage draw. Refer to Specifications for starter motor free running test maximum amperage draw specifications. 7. If ammeter reading exceeds maximum amperage draw specification, replace faulty starter motor assembly. STARTER SOLENOID Certain vehicles with certain engines may require starter motor removal for the following test. 1. If necessary, remove starter motor from vehicle. 2. Disconnect solenoid connector wiring from starter motor. 3. Check for continuity between solenoid terminal (2) and solenoid case (3). There should be continuity. If not OK, replace faulty starter motor assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Removal Starter Motor: Service and Repair Removal REMOVAL 5.9L Diesel 1. Disconnect and isolate both negative battery cables at both batteries. 2. Raise and support vehicle. 3. Remove 3 starter mounting bolts . 4. Move starter motor towards front of vehicle far enough for nose of starter pinion housing to clear housing. Always support starter motor during this process. Do not let starter motor hang from wire harness. 5. Tilt nose downwards and lower starter motor far enough to access and remove nuts securing starter wiring harness to starter . Do not let starter motor hang from wire harness. 6. Remove starter motor from engine. Note: Certain diesel engines use an aluminum spacer . Note position and orientation of spacer before removal. 6.7L Diesel 1. Disconnect and isolate both negative battery cables at both batteries. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Removal > Page 11815 2. Raise and support vehicle. 3. Disconnect solenoid electrical connector (3). 4. Remove battery cable mounting nut (2). 5. Remove battery cable (1) from stud. 6. Remove three starter mounting bolts (4). 7. Remove starter motor from engine. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Removal > Page 11816 Starter Motor: Service and Repair Installation INSTALLATION 5.9L Diesel 1. If Equipped: Position and hold aluminum spacer to rear of starter while positioning starter to engine. 2. Connect solenoid wire to starter motor. Tighten nut to 4.4 ft. lbs. (6 Nm).. 3. Position battery cable to starter stud. Install and tighten battery cable nut to 10.3 ft. lbs. (14 Nm). Do not allow starter motor to hang from wire harness. 4. Position starter motor to transmission. 5. If equipped with automatic transmission, slide cooler tube bracket into position. 6. Install and tighten 3 starter mounting bolts to 32 ft. lbs. (43 Nm). 7. Lower vehicle. 8. Connect both negative battery cables to both batteries. 6.7L Diesel 1. Connect solenoid wire to starter motor. Tighten nut to 4.4 ft. lbs. (6 Nm).. 2. Position battery cable to starter stud. Install and tighten battery cable nut to 10.3 ft. lbs. (14 Nm). Do not allow starter motor to hang from wire harness. 3. Position starter motor to transmission. 4. Install and tighten 3 starter mounting bolts to 32 ft. lbs. (43 Nm). 5. Lower vehicle. 6. Connect both negative battery cables to both batteries. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Diagrams Relay - Starter Motor (Except SRT) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations Auxiliary Power Outlet: Locations Component ID: 234 Component : POWER OUTLET Connector: Name : POWER OUTLET Color : GRAY # of pins : 3 Pin Description Circuit 1 FUSED B(+) A205 18RD/OR 2-3 GROUND Z737 18BK/LB Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Page 11824 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11827 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11828 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11829 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11830 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11831 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11832 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11833 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11834 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11835 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11836 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11837 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11838 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11839 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11840 Auxiliary Power Outlet: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11841 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11842 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11843 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11844 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11845 Auxiliary Power Outlet: Connector Views Power Outlet Component ID: 234 Component : POWER OUTLET Connector: Name : POWER OUTLET Color : GRAY # of pins : 3 Pin Description Circuit 1 FUSED B(+) A205 18RD/OR 2-3 GROUND Z737 18BK/LB Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11846 Power Outlet-Console Component ID: 235 Component : POWER OUTLET-CONSOLE Connector: Name : POWER OUTLET-CONSOLE Color : GRAY # of pins : 3 Pin Description Circuit Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11847 1 FUSED B(+) A405 18BR Pin Description Circuit 1 FUSED B(+) A405 18RD/DB 2-3 GROUND Z939 18BK Power Outlet-Lower Console Component ID: 236 Component : POWER OUTLET-LOWER CONSOLE Connector: Name : POWER OUTLET-LOWER CONSOLE Color : # of pins : 3 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F984 16PK/YL 2-- 3 GROUND Z939 18BK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11848 Auxiliary Power Outlet: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-41-02 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11849 8w-41-03 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11850 8w-41-04 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Power Outlet-Instrument Panel Auxiliary Power Outlet: Description and Operation Power Outlet-Instrument Panel Description DESCRIPTION A cigar lighter outlet is installed to the left of the center stack area in the lower instrument panel. The cigar lighter outlet is secured by a snap fit within the bezel. The cigar lighter outlet, plastic cap and the knob and heating element unit are available for service replacement. These components cannot be repaired and, if inoperative or damaged, they must be replaced. Operation OPERATION The cigar lighter consists of two major components: a knob and heating element unit, and the cigar lighter base or outlet shell. The receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The cigar lighter receives battery voltage from a fuse in the Integrated Power Module (IPM) when the ignition switch is in the Accessory or Run positions. The cigar lighter knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating element are inserted in the outlet shell, the heating element resistor coil is grounded through its housing to the outlet shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating element, and the heating element extends from the housing toward the insulated contact in the bottom of the outlet shell. Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the outlet shell. These clips engage and hold the heating element against the insulated contact long enough for the resistor coil to heat up. When the heating element is engaged with the contact, battery current can flow through the resistor coil to ground, causing the resistor coil to heat. When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating element, the spring-loaded housing forces the knob and heating element to pop back outward to their relaxed position. When the cigar lighter knob and element are pulled out of the outlet shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Power Outlet-Instrument Panel > Page 11853 Auxiliary Power Outlet: Description and Operation Power Outlet-Console Description DESCRIPTION Two power outlets are utilized on this model. One in the instrument panel center lower bezel and the other in the center console. The power outlet bases are secured by a snap fit within the instrument panel or trim panel. A plastic protective cap snaps into the power outlet base when the power outlet is not being used, and hangs from the power outlet base mount by an integral bail strap while the power outlet is in use. The power outlet receptacle unit and the accessory power outlet protective cap are available for service. The power outlet receptacle cannot be repaired and, if faulty or damaged, it must be replaced. Operation OPERATION The power outlet base or receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet receives battery voltage from a fuse in the integrated power module at all times. While the power outlet is very similar to a cigar lighter base unit, it does not include the two small spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar lighter heating element to the insulated contact. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Cigar Lighter Outlet Auxiliary Power Outlet: Testing and Inspection Cigar Lighter Outlet CIGAR LIGHTER OUTLET For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Check the fused B(+) fuse in the Integrated Power Module (IPM). If OK, go to STEP 2. If not OK, repair the shorted circuit or component as required and replace the inoperative fuse. 2. Turn the ignition switch to the Run position. Check for battery voltage at the fused B(+) fuse in the IPM. If OK, go to STEP 3. If not OK, repair the open or short as required. 3. Remove the cigar lighter knob and element from the cigar lighter outlet shell. Check for continuity between the inside circumference of the cigar lighter outlet shell and a good ground. there should be continuity. If OK, go to STEP 4. If not OK, go to STEP 5. 4. Turn the ignition switch to the Run position. Check for battery voltage at the insulated contact located at the back of the cigar lighter outlet shell. If OK, replace the inoperative cigar lighter knob and element. If not OK, go to STEP 5. 5. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Check for continuity between the ground circuit cavity of the cigar lighter wire harness connector and a good ground. There should be continuity. If OK, go to STEP 6. If not OK, repair the open ground circuit to ground as required. 6. Connect the battery negative cable. Turn the ignition switch to the Accessory or Run positions. Check for battery voltage at the fused B(+) circuit cavity of the cigar lighter wire harness connector. If OK, replace the inoperative cigar lighter outlet. If not OK, repair the open fused B(+) circuit to the IPM fuse as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Cigar Lighter Outlet > Page 11856 Auxiliary Power Outlet: Testing and Inspection Power Outlet POWER OUTLET For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Check the fused B(+) fuse in the Integrated Power Module (IPM). If OK, go to STEP 2. If not OK, repair the shorted circuit or component as required and replace the inoperative fuse. 2. Turn the ignition switch to the Run position. Check for battery voltage at the fused B(+) fuse in the IPM. If OK, go to STEP 3. If not OK, repair the open or short as required. 3. Remove the cigar lighter knob and element from the cigar lighter outlet shell. Check for continuity between the inside circumference of the cigar lighter outlet shell and a good ground. there should be continuity. If OK, go to STEP 4. If not OK, go to STEP 5. 4. Turn the ignition switch to the Run position. Check for battery voltage at the insulated contact located at the back of the cigar lighter outlet shell. If OK, replace the inoperative cigar lighter knob and element. If not OK, go to STEP 5. 5. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Check for continuity between the ground circuit cavity of the cigar lighter wire harness connector and a good ground. There should be continuity. If OK, go to STEP 6. If not OK, repair the open ground circuit to ground as required. 6. Connect the battery negative cable. Turn the ignition switch to the Accessory or Run positions. Check for battery voltage at the fused B(+) circuit cavity of the cigar lighter wire harness connector. If OK, replace the inoperative cigar lighter outlet. If not OK, repair the open fused B(+) circuit to the IPM fuse as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Power Outlet-Instrument Panel Auxiliary Power Outlet: Service and Repair Power Outlet-Instrument Panel Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Pull the cigar lighter knob and element (1) out of the cigar lighter receptacle base (6), or unsnap the protective cap from the power outlet receptacle base (6). 3. Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangular retaining bosses (3) of the mount that secures the receptacle base to the panel (4). 4. Insert a pair of external snap ring pliers (5) into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 5. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount. 6. Pull the receptacle base away from the instrument panel far enough to access the instrument panel wire harness connector (2). 7. Disconnect the instrument panel wire harness connector (2) from the cigar lighter or power outlet receptacle base (6). 8. Remove the cigar lighter or power outlet mount from the instrument panel. Installation INSTALLATION 1. Connect the instrument panel wire harness connector to the cigar lighter or power outlet receptacle base connector receptacle. 2. Install the cigar lighter or power outlet mount into the instrument panel. 3. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 4. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 5. Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base. 6. Connect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Power Outlet-Instrument Panel > Page 11859 Auxiliary Power Outlet: Service and Repair Power Outlet-Console Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Pull the cigar lighter knob and element (1) out of the cigar lighter receptacle base (6), or unsnap the protective cap from the power outlet receptacle base (6). 3. Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangular retaining bosses (3) of the mount that secures the receptacle base to the panel (4). 4. Insert a pair of external snap ring pliers (5) into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 5. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount. 6. Pull the receptacle base away from the instrument panel far enough to access the instrument panel wire harness connector (2). 7. Disconnect the instrument panel wire harness connector (2) from the cigar lighter or power outlet receptacle base (6). 8. Remove the cigar lighter or power outlet mount from the instrument panel. Installation INSTALLATION 1. Connect the instrument panel wire harness connector to the cigar lighter or power outlet receptacle base connector receptacle. 2. Install the cigar lighter or power outlet mount into the instrument panel. 3. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 4. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 5. Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base. 6. Connect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations Electrical Accessory Panel: Locations Component ID: 233 Component : PORT-UPFITTERS Connector: Name : PORT-UPFITTERS Color : # of pins : 10 Pin Description Circuit 1 PTO SENSE G113 18PK/YL Pin Description Circuit 1 RUN RELAY OUTPUT F923 16PK/YL Pin Description Circuit 1 IN CAB POWER TAKEOFF SWITCH INPUT K425 16PK/YL 2 S/C SWITCH RETURN V937 18VT/BR 3 POWER TAKEOFF SYSTEM STATUS BULB G425 18VT/YL 4 FUSED IGNITION SWITCH OUTPUT (RUN) F922 16PK/RD 5 FUSED B(+) A423 14PK 6 FUSED B(+) A423 14PK 7 FUSED B(+) A422 14RD 8 FUSED B(+) A422 14RD 9 FUSED B(+) A426 14VT 10 - Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 11863 Connector: Name : PORT-UPFITTERS Color : # of pins : 10 Pin Description Circuit 1 RUN RELAY OUTPUT F923 16PK/YL 2 S/C SWITCH RETURN V937 18VT/BR 3 POWER TAKEOFF SYSTEM STATUS BULB G425 18VT/YL 4 FUSED IGNITION SWITCH OUTPUT (RUN) F922 16PK/RD 5 FUSED B(+) A423 14PK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 11864 6 FUSED B(+) A423 14PK 7 FUSED B(+) A422 14RD 8 FUSED B(+) A422 14RD 9 FUSED B(+) A426 14VT 10 - Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 11865 Electrical Accessory Panel: Diagrams Component ID: 233 Component : PORT-UPFITTERS Connector: Name : PORT-UPFITTERS Color : # of pins : 10 Pin Description Circuit 1 PTO SENSE G113 18PK/YL Pin Description Circuit 1 RUN RELAY OUTPUT F923 16PK/YL Pin Description Circuit 1 IN CAB POWER TAKEOFF SWITCH INPUT K425 16PK/YL 2 S/C SWITCH RETURN V937 18VT/BR 3 POWER TAKEOFF SYSTEM STATUS BULB G425 18VT/YL 4 FUSED IGNITION SWITCH OUTPUT (RUN) F922 16PK/RD 5 FUSED B(+) A423 14PK 6 FUSED B(+) A423 14PK 7 FUSED B(+) A422 14RD 8 FUSED B(+) A422 14RD 9 FUSED B(+) A426 14VT 10 - Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 11866 Connector: Name : PORT-UPFITTERS Color : # of pins : 10 Pin Description Circuit 1 RUN RELAY OUTPUT F923 16PK/YL 2 S/C SWITCH RETURN V937 18VT/BR 3 POWER TAKEOFF SYSTEM STATUS BULB G425 18VT/YL 4 FUSED IGNITION SWITCH OUTPUT (RUN) F922 16PK/RD 5 FUSED B(+) A423 14PK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 11867 6 FUSED B(+) A423 14PK 7 FUSED B(+) A422 14RD 8 FUSED B(+) A422 14RD 9 FUSED B(+) A426 14VT 10 - Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation Fuse: Customer Interest Electrical Systems - Intermittent Component Operation NUMBER:08-016-06 REV. A GROUP: Electrical DATE: July 18, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-016-06, DATED MARCH 22, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF A VEHICLE BODY STYLE. SUBJECT: Intermittent Operation Of Electrical Components Due To Ignition Off Draw (IOD) Fuse Not Being Fully Seated MODELS: 2007 (PM) Caliber **2007 (MK-49) Compass** 2006 - 2007 (DHIDRID1) Ram Truck 2006 - 2007 (PT) Chrysler PT Cruiser DISCUSSION: The Ignition Off Draw (IOD) fuse is used to prevent battery discharge during shipping and long term storage of the vehicles. The IOD fuse is located in the Total Integrated Power Module (TI PM). If the fuse is not completely inserted partial contact of the fuse terminals could occur. When the vehicle is prepped for customer delivery, ensure that the fuse is fully engaged (Fig. 1). The IOD fuse must also be fully released to prevent battery drain from occurring when the vehicle is stored. When the IOD fuse holder is depressed into the carrier, an initial distinct detent will be felt to overcome the "pre-hold position". You must then continue to push straight down on the IOD pre-holder until no further downward movement is encountered. NOTE: If the fuse is not pushed down symmetrically, two detents MAY be felt as each side snaps past the pre-hold position. Push down until no further downward movement is encountered. On 2006 and 2007 PT and PM vehicles the circuits fed by the IOD fuse are: Radio, Security module & siren (BUX), Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Power Mirrors, Clock, Memory Seat, Amplifier, CCN wake-up with ignition off and Homelink. On 2006 and 2007 DR, DH or D1 vehicles the circuits fed by the IOD fuse are: Radio, EVIC, Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Video Screen, CCN wake-up with ignition off, Underhood Lamp, CCN Interior Lighting Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation > Page 11876 POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems Intermittent Component Operation Fuse: All Technical Service Bulletins Electrical Systems - Intermittent Component Operation NUMBER:08-016-06 REV. A GROUP: Electrical DATE: July 18, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-016-06, DATED MARCH 22, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF A VEHICLE BODY STYLE. SUBJECT: Intermittent Operation Of Electrical Components Due To Ignition Off Draw (IOD) Fuse Not Being Fully Seated MODELS: 2007 (PM) Caliber **2007 (MK-49) Compass** 2006 - 2007 (DHIDRID1) Ram Truck 2006 - 2007 (PT) Chrysler PT Cruiser DISCUSSION: The Ignition Off Draw (IOD) fuse is used to prevent battery discharge during shipping and long term storage of the vehicles. The IOD fuse is located in the Total Integrated Power Module (TI PM). If the fuse is not completely inserted partial contact of the fuse terminals could occur. When the vehicle is prepped for customer delivery, ensure that the fuse is fully engaged (Fig. 1). The IOD fuse must also be fully released to prevent battery drain from occurring when the vehicle is stored. When the IOD fuse holder is depressed into the carrier, an initial distinct detent will be felt to overcome the "pre-hold position". You must then continue to push straight down on the IOD pre-holder until no further downward movement is encountered. NOTE: If the fuse is not pushed down symmetrically, two detents MAY be felt as each side snaps past the pre-hold position. Push down until no further downward movement is encountered. On 2006 and 2007 PT and PM vehicles the circuits fed by the IOD fuse are: Radio, Security module & siren (BUX), Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Power Mirrors, Clock, Memory Seat, Amplifier, CCN wake-up with ignition off and Homelink. On 2006 and 2007 DR, DH or D1 vehicles the circuits fed by the IOD fuse are: Radio, EVIC, Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Video Screen, CCN wake-up with ignition off, Underhood Lamp, CCN Interior Lighting Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems Intermittent Component Operation > Page 11882 POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses (Integrated Power Module) Fuse: Locations Fuses (Integrated Power Module) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses (Integrated Power Module) > Page 11885 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses (Integrated Power Module) > Page 11886 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses (Integrated Power Module) > Page 11887 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses (Integrated Power Module) > Page 11888 Fuse: Locations Auxiliary PDC Box (Upfitter Package) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 11891 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 11892 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 11893 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 11894 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 11895 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 11896 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 11897 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 11898 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 11899 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 11900 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 11901 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 11902 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 11903 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 11904 Fuse: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 11905 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 11906 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 11907 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 11908 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses (Integrated Power Module) Fuse: Application and ID Fuses (Integrated Power Module) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 11911 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 11912 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 11913 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 11914 Fuse: Application and ID Auxiliary PDC Box (Upfitter Package) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Description and Operation > Description Fuse: Description and Operation Description DESCRIPTION All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Totally Integrated Power Module (TIPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the TIPM as part of the new vehicle preparation procedures and then disconnect it again until new vehicle delivery to the customer. A laser printed fuse layout map is integral to the TIPM cover to ensure proper fuse identification. The IOD fuse is a 20 ampere mini blade-type fuse. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in the TIPM cavity, and as a fuse holder that conveniently stores the fuse in the same cavity after it has been disconnected. CIRCUITS INCLUDED WITH IOD FUSE - Cluster (CCN) - Diagnostic Connector - Map Lamps - Glove Box Lamp - Courtesy Lamps - Radio - Underhood Lamp Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Description and Operation > Description > Page 11917 Fuse: Description and Operation Operation OPERATION The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from Integrated Power Module (IPM) fuse cavity # 51 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses (Integrated Power Module) Fuse Block: Locations Fuses (Integrated Power Module) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses (Integrated Power Module) > Page 11922 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses (Integrated Power Module) > Page 11923 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses (Integrated Power Module) > Page 11924 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses (Integrated Power Module) > Page 11925 Fuse Block: Locations Auxiliary PDC Box (Upfitter Package) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11928 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11929 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11930 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11931 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11932 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11933 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11934 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11935 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11936 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11937 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11938 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11939 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11940 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11941 Fuse Block: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11942 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11943 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11944 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11945 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses (Integrated Power Module) Fuse Block: Application and ID Fuses (Integrated Power Module) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 11948 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 11949 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 11950 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 11951 Fuse Block: Application and ID Auxiliary PDC Box (Upfitter Package) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Power Distribution Module: Customer Interest Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 11960 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 11961 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 11962 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 11963 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: Customer Interest Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 11968 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 11969 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 11970 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 11971 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Power Distribution Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 11977 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 11978 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 11979 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 11980 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: All Technical Service Bulletins Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 11985 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 11986 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 11987 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 11988 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead Power Distribution Module: Locations Module-Electronic Overhead Component ID: 202 Component : MODULE-ELECTRONIC OVERHEAD Connector: Name : MODULE-ELECTRONIC OVERHEAD Color : BLACK # of pins : 6 Qualifier : (EXCEPT BASE) Pin Description Circuit 1-2 FUSED B(+) A114 18GY/RD 3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT 5 GROUND Z13 20BK/WT 6-- Component Location - 53 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 11991 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 11992 Power Distribution Module: Locations Module-Totally Integrated Power Component ID: 213 Component : MODULE-TOTALLY INTEGRATED POWER Connector: Name : MODULE-TOTALLY INTEGRATED POWER C1 Color : LT. GRAY # of pins : 14 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 2 TRS T41 SIGNAL (P/N) T41 18YL/DB 2 TRS T41 SIGNAL (P/N) T41 20YL/DB 2 STARTER SOLENOID CONTROL T752 20DG/OR 3-4 FUEL PUMP CONTROL K31 20BR 5 WIPER PARK SWITCH SENSE W7 20BR/GY 6-7-8 WASHER FLUID SWITCH RETURN G932 20VT/TN 9 WASHER FLUID SWITCH SENSE W1 20BR/TN 10 TRANSMISSION CONTROL T515 20YL/DB 11 HOOD AJAR SWITCH SENSE G70 20VT/LB 12 - 13 - 14 - Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 11993 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 11994 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C10 Color : LT. GRAY # of pins : 22 Pin Description Circuit 1 ASD CONTROL OUTPUT K342 16BR/WT 2 FUSED B(+) A405 18RD/DB 3 FUSED B(+) A941 18RD 4-5 FUSED B(+) A104 20YL/RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 11995 6 FUSED B(+) A310 16RD/LB 7 REAR WINDOW DEFOGGER CONTROL OUTPUT C15 14DB/WT 8 FUSED IGNITION SWITCH OUTPUT (RUN-START) F12 14PK/RD 9 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 10 - 11 HORN CONTROL OUTPUT X22 18GY/LB 12 WIPER LOW SPEED CONTROL OUTPUT W3 18BR/WT 13 GROUND Z971 18BK 14 HEATED MIRROR CONTROL OUTPUT C16 18DB/GY 15 FUSED B(+) A212 20RD/OR 16 - - 17 FUSED B(+) A121 14RD/YL 18 FUEL PUMP CONTROL OUTPUT A109 16OR/RD 19 HORN CONTROL OUTPUT X21 18GY/YL 20 GROUND Z953 20BK 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 FUSED B(+) A400 14TN/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 11996 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C2 Color : BLACK # of pins : 13 Pin Description Circuit 1-2 WASHER PUMP MOTOR CONTROL W10 20BR 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 ADJUSTABLE PEDALS OUTPUT A72 20RD/OR 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 11997 6-7-8-9 FRONT AXLE LOCK CONTROL G304 20VT/DB 10 A/C CLUTCH CONTROL C13 20LB 10 A/C CLUTCH CONTROL C13 20LB/OR 11 ASD CONTROL K51 20BR/WT 12 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/OR 13 GROUND Z117 20BK/WT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 11998 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C3 Color : BLACK # of pins : 22 Pin Description Circuit 1 FUSED B(+) A209 10RD 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F984 18PK/YL 4-5 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F983 20PK/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 11999 6 FUSED B(+) A205 18RD/OR 7-8 FUSED B(+) A944 20RD 9 FUSED B(+) A116 16YL/RD 10 FUSED B(+) A118 18RD/OR 11 - 12 FUSED B(+) A918 20RD 12 FUSED B(+) A918 16RD 13 FUSED IGNITION SWITCH OUTPUT (RUN) F921 20PK/LB 14 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 15 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 16 FUSED B(+) A930 16RD 17 FUSED IGNITION SWITCH OUTPUT (RUN-START) F942 10PK/LG 18 TRAILER TOW LEFT TURN RELAY OUTPUTL673 18YL 19 TRAILER TOW RIGHT TURN RELAY OUTPUT L674 18LG 20 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 21 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 22 FUSED IGNITION SWITCH OUTPUT (RUN-START) F12 14PK/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12000 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C4 Color : LT. GRAY # of pins : 13 Pin Description Circuit 1 GROUND Z118 16BK/YL 2 SHIFT MOTOR CONTROL A T102 16YL 3 SHIFT MOTOR CONTROL B T101 16DG 4-5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12001 6-7-8 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 9 5 VOLT SUPPLY T103 20YL/OR 10 MODE SENSOR A D201 20WT/DG 11 SENSOR RETURN G180 20VT/YL 12 FUSED B(+) A880 20DB/RD 13 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12002 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C5 Color : BLACK # of pins : 10 Pin Description Circuit 1 LEFT FRONT TURN LAMP DRIVER L61 20WT/LG 2 RIGHT FRONT TURN LAMP DRIVER L60 20WT/TN 3 RIGHT HIGH BEAM DRIVER L34 20WT/GY 4 LEFT LOW BEAM DRIVER L43 20WT/DB 5 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12003 6-7-8 AAT SIGNAL G31 20VT/LG 9 AAT RETURN G930 20VT/TN 10 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12004 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C6 Color : BROWN # of pins : 16 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/LG 2 DIAGNOSTIC CAN C (+) D52 20WT/LB 3 CAN B BUS (+) D55 20WT/OR 4 LEFT REAR TURN LAMP DRIVER L63 20WT/DG 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12005 6 RIGHT REAR TURN LAMP DRIVER L62 20WT/YL 7 BRAKE LAMP SWITCH OUTPUT L50 20WT/TN 8-9 CAN C BUS (-) D64 20WT/LB 10 DIAGNOSTIC CAN C (-) D51 20WT/BR 11 CAN B BUS (-) D54 20WT 12 - 13 - 14 - 15 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 16 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12006 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C7 Color : BLUE # of pins : 14 Pin Description Circuit 1-2-3 RIGHT LOW BEAM DRIVER L44 20WT/TN 4 LEFT HIGH BEAM DRIVER L33 20WT/LG 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12007 6-7 A/C PRESSURE 5 VOLT SUPPLY C818 20LB/OR 8 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY 9-10 - 11 - 12 A/C PRESSURE SIGNAL C18 20LB/BR 13 A/C PRESSURE GROUND C918 20BK/LB 14 IGNITION START T751 20YL Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12008 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C8 Color : LT. GRAY # of pins : 12 Pin Description Circuit 1-2 FUSED B(+) A919 20RD 3 FUSED B(+) A106 20LB/RD 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 5 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20PK/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12009 6 FUSED B(+) A100 14RD/VT 7 FUSED B(+) A210 12OR/RD 8 FUSED B(+) A940 18RD 9 FUSED B(+) A103 18GY/RD 10 FOG LAMP CONTROL OUTPUT L89 18WT/YL 11 BACKUP LAMP FEED L1 18WT/LG 12 FUEL HEATER CONTROL OUTPUT A961 14RD 12 CONDENSER FAN CONTROL OUTPUT C123 12LB/WT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12010 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C9 Color : BLACK # of pins : 12 Pin Description Circuit 1 FUSED B(+) A111 16DG/RD 2 STARTER MOTOR CONTROL OUTPUT T750 14YL/GY 3 A/C CLUTCH CONTROL OUTPUT C3 20DB/YL 4 WIPER MOTOR HIGH SPEED FEED W4 16BR/OR 5 FUSED B(+) A114 18GY/RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12011 6 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 10PK/YL 7-8 FUSED PARK LAMP FEED L7 20WT/YL 9 FUSED PARK LAMP FEED L678 18BR 10 FUSED PARK LAMP FEED L70 20WT/GY 11 - 12 FUSED B(+) A107 12TN/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12012 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (DIESEL) Pin Description Circuit 1 B(+) A0 6RD Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12013 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12014 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (GAS) Pin Description Circuit 1 B(+) A11 8LB Pin Description Circuit 1 B(+) A0 6RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12015 Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12016 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12017 Power Distribution Module: Locations Auxiliary PDC Box Component ID: 22 Component : AUXILIARY PDC BOX Connector: Name : AUXILIARY PDC BOX Color : # of pins : 10 Qualifier : (UPFITTER PACKAGE) Pin Description Circuit 1 FUSED B(+) A420 10RD 2 3 FUSED B(+) A420 10RD 4 FUSED B(+) A422 14RD 5 FUSED B(+) A420 10RD 6 FUSED B(+) A423 14PK 7 8 FUSED IGNITION SWITCH OUTPUT (RUN) F922 16PK/RD 9 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 10 GROUND Z912 20BK Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12018 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead Power Distribution Module: Diagrams Module-Electronic Overhead Component ID: 202 Component : MODULE-ELECTRONIC OVERHEAD Connector: Name : MODULE-ELECTRONIC OVERHEAD Color : BLACK # of pins : 6 Qualifier : (EXCEPT BASE) Pin Description Circuit 1-2 FUSED B(+) A114 18GY/RD 3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT 5 GROUND Z13 20BK/WT 6-- Component Location - 53 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12021 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12022 Power Distribution Module: Diagrams Module-Totally Integrated Power Component ID: 213 Component : MODULE-TOTALLY INTEGRATED POWER Connector: Name : MODULE-TOTALLY INTEGRATED POWER C1 Color : LT. GRAY # of pins : 14 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 2 TRS T41 SIGNAL (P/N) T41 18YL/DB 2 TRS T41 SIGNAL (P/N) T41 20YL/DB 2 STARTER SOLENOID CONTROL T752 20DG/OR 3-4 FUEL PUMP CONTROL K31 20BR 5 WIPER PARK SWITCH SENSE W7 20BR/GY 6-7-8 WASHER FLUID SWITCH RETURN G932 20VT/TN 9 WASHER FLUID SWITCH SENSE W1 20BR/TN 10 TRANSMISSION CONTROL T515 20YL/DB 11 HOOD AJAR SWITCH SENSE G70 20VT/LB 12 - 13 - 14 - Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12023 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12024 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C10 Color : LT. GRAY # of pins : 22 Pin Description Circuit 1 ASD CONTROL OUTPUT K342 16BR/WT 2 FUSED B(+) A405 18RD/DB 3 FUSED B(+) A941 18RD 4-5 FUSED B(+) A104 20YL/RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12025 6 FUSED B(+) A310 16RD/LB 7 REAR WINDOW DEFOGGER CONTROL OUTPUT C15 14DB/WT 8 FUSED IGNITION SWITCH OUTPUT (RUN-START) F12 14PK/RD 9 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 10 - 11 HORN CONTROL OUTPUT X22 18GY/LB 12 WIPER LOW SPEED CONTROL OUTPUT W3 18BR/WT 13 GROUND Z971 18BK 14 HEATED MIRROR CONTROL OUTPUT C16 18DB/GY 15 FUSED B(+) A212 20RD/OR 16 - - 17 FUSED B(+) A121 14RD/YL 18 FUEL PUMP CONTROL OUTPUT A109 16OR/RD 19 HORN CONTROL OUTPUT X21 18GY/YL 20 GROUND Z953 20BK 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 FUSED B(+) A400 14TN/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12026 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C2 Color : BLACK # of pins : 13 Pin Description Circuit 1-2 WASHER PUMP MOTOR CONTROL W10 20BR 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 ADJUSTABLE PEDALS OUTPUT A72 20RD/OR 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12027 6-7-8-9 FRONT AXLE LOCK CONTROL G304 20VT/DB 10 A/C CLUTCH CONTROL C13 20LB 10 A/C CLUTCH CONTROL C13 20LB/OR 11 ASD CONTROL K51 20BR/WT 12 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/OR 13 GROUND Z117 20BK/WT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12028 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C3 Color : BLACK # of pins : 22 Pin Description Circuit 1 FUSED B(+) A209 10RD 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F984 18PK/YL 4-5 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F983 20PK/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12029 6 FUSED B(+) A205 18RD/OR 7-8 FUSED B(+) A944 20RD 9 FUSED B(+) A116 16YL/RD 10 FUSED B(+) A118 18RD/OR 11 - 12 FUSED B(+) A918 20RD 12 FUSED B(+) A918 16RD 13 FUSED IGNITION SWITCH OUTPUT (RUN) F921 20PK/LB 14 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 15 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 16 FUSED B(+) A930 16RD 17 FUSED IGNITION SWITCH OUTPUT (RUN-START) F942 10PK/LG 18 TRAILER TOW LEFT TURN RELAY OUTPUTL673 18YL 19 TRAILER TOW RIGHT TURN RELAY OUTPUT L674 18LG 20 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 21 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 22 FUSED IGNITION SWITCH OUTPUT (RUN-START) F12 14PK/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12030 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C4 Color : LT. GRAY # of pins : 13 Pin Description Circuit 1 GROUND Z118 16BK/YL 2 SHIFT MOTOR CONTROL A T102 16YL 3 SHIFT MOTOR CONTROL B T101 16DG 4-5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12031 6-7-8 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 9 5 VOLT SUPPLY T103 20YL/OR 10 MODE SENSOR A D201 20WT/DG 11 SENSOR RETURN G180 20VT/YL 12 FUSED B(+) A880 20DB/RD 13 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12032 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C5 Color : BLACK # of pins : 10 Pin Description Circuit 1 LEFT FRONT TURN LAMP DRIVER L61 20WT/LG 2 RIGHT FRONT TURN LAMP DRIVER L60 20WT/TN 3 RIGHT HIGH BEAM DRIVER L34 20WT/GY 4 LEFT LOW BEAM DRIVER L43 20WT/DB 5 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12033 6-7-8 AAT SIGNAL G31 20VT/LG 9 AAT RETURN G930 20VT/TN 10 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12034 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C6 Color : BROWN # of pins : 16 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/LG 2 DIAGNOSTIC CAN C (+) D52 20WT/LB 3 CAN B BUS (+) D55 20WT/OR 4 LEFT REAR TURN LAMP DRIVER L63 20WT/DG 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12035 6 RIGHT REAR TURN LAMP DRIVER L62 20WT/YL 7 BRAKE LAMP SWITCH OUTPUT L50 20WT/TN 8-9 CAN C BUS (-) D64 20WT/LB 10 DIAGNOSTIC CAN C (-) D51 20WT/BR 11 CAN B BUS (-) D54 20WT 12 - 13 - 14 - 15 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 16 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12036 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C7 Color : BLUE # of pins : 14 Pin Description Circuit 1-2-3 RIGHT LOW BEAM DRIVER L44 20WT/TN 4 LEFT HIGH BEAM DRIVER L33 20WT/LG 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12037 6-7 A/C PRESSURE 5 VOLT SUPPLY C818 20LB/OR 8 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY 9-10 - 11 - 12 A/C PRESSURE SIGNAL C18 20LB/BR 13 A/C PRESSURE GROUND C918 20BK/LB 14 IGNITION START T751 20YL Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12038 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C8 Color : LT. GRAY # of pins : 12 Pin Description Circuit 1-2 FUSED B(+) A919 20RD 3 FUSED B(+) A106 20LB/RD 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 5 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20PK/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12039 6 FUSED B(+) A100 14RD/VT 7 FUSED B(+) A210 12OR/RD 8 FUSED B(+) A940 18RD 9 FUSED B(+) A103 18GY/RD 10 FOG LAMP CONTROL OUTPUT L89 18WT/YL 11 BACKUP LAMP FEED L1 18WT/LG 12 FUEL HEATER CONTROL OUTPUT A961 14RD 12 CONDENSER FAN CONTROL OUTPUT C123 12LB/WT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12040 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C9 Color : BLACK # of pins : 12 Pin Description Circuit 1 FUSED B(+) A111 16DG/RD 2 STARTER MOTOR CONTROL OUTPUT T750 14YL/GY 3 A/C CLUTCH CONTROL OUTPUT C3 20DB/YL 4 WIPER MOTOR HIGH SPEED FEED W4 16BR/OR 5 FUSED B(+) A114 18GY/RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12041 6 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 10PK/YL 7-8 FUSED PARK LAMP FEED L7 20WT/YL 9 FUSED PARK LAMP FEED L678 18BR 10 FUSED PARK LAMP FEED L70 20WT/GY 11 - 12 FUSED B(+) A107 12TN/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12042 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (DIESEL) Pin Description Circuit 1 B(+) A0 6RD Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12043 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12044 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (GAS) Pin Description Circuit 1 B(+) A11 8LB Pin Description Circuit 1 B(+) A0 6RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12045 Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12046 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12047 Power Distribution Module: Diagrams Auxiliary PDC Box Component ID: 22 Component : AUXILIARY PDC BOX Connector: Name : AUXILIARY PDC BOX Color : # of pins : 10 Qualifier : (UPFITTER PACKAGE) Pin Description Circuit 1 FUSED B(+) A420 10RD 2 3 FUSED B(+) A420 10RD 4 FUSED B(+) A422 14RD 5 FUSED B(+) A420 10RD 6 FUSED B(+) A423 14PK 7 8 FUSED IGNITION SWITCH OUTPUT (RUN) F922 16PK/RD 9 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 10 GROUND Z912 20BK Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12048 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Description Power Distribution Module: Description and Operation Description DESCRIPTION The Totally Integrated Power Module (2)(TIPM) is a combination unit that performs the functions of the Power Distribution Center (PDC) and the Front Control Module. The TIPM is a printed circuit board based module that contains fuses, internal relays and a microprocessor that performs the functions previously executed by the FCM. The TIPM (2) is located in the engine compartment, next to the battery (1) and connects directly to the B+ cable (5) via a stud located on top of the unit. The ground connection is via electrical connectors. The TIPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic TIPM housing includes a base and cover. The TIPM cover is easily opened or removed for service and has a fuse and relay layout map integral to the inside surface of the cover. The TIPM housing base and cover are secured in place via mounting tabs. The mounting tabs secure the TIPM (2) to the battery tray mounting bracket (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Description > Page 12051 Power Distribution Module: Description and Operation Operation OPERATION All of the current from the battery and the generator output enters the Totally Integrated Power Module (TIPM) via a stud on the top of the module. The TIPM cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal Power Distribution Module: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the B+ terminal nut (6) from the Totally Integrated Power Module (2)(TIPM) B+ terminal. Remove the B+ cable (5) from the TIPM (2). 3. Using a suitable flat blade tool, disengage the TIPM (2) upper retaining tabs from the battery tray bracket (3). 4. Grasp the TIPM (1) and rotate the assembly up to free it from its mounting bracket (3). Position the assembly upside down to access the electrical connectors located on the bottom of the unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal > Page 12054 5. Disconnect the electrical connectors (2) by depressing the locking tab and rotating the connector arm outboard, until the connector is free from the TIPM assembly (1). Be certain to pull the connectors straight off. 6. Remove the TIPM (1) from the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal > Page 12055 Power Distribution Module: Service and Repair Installation INSTALLATION 1. Position the Totally Integrated Power Module (1)(TIPM) into the vehicle. NOTE: Totally Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors (2) by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the TIPM assembly (1). 3. Turn the TIPM (1) so that the connector side is facing down. Install the assembly onto the TIPM battery tray bracket (3) making sure to line up the lower retaining tab with the retaining slot in the tray (1). 4. Push the TIPM (1) downward to lock the upper retaining clips into the bracket (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal > Page 12056 5. Install the B+ terminal cable (5) and nut (6) on the B+ terminal of the TIPM (2). 6. Connect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Power Distribution Module: Customer Interest Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 12066 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 12067 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 12068 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 12069 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: Customer Interest Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12074 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12075 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12076 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12077 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Power Distribution Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 12083 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 12084 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 12085 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 12086 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: All Technical Service Bulletins Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12091 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12092 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12093 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12094 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead Power Distribution Module: Locations Module-Electronic Overhead Component ID: 202 Component : MODULE-ELECTRONIC OVERHEAD Connector: Name : MODULE-ELECTRONIC OVERHEAD Color : BLACK # of pins : 6 Qualifier : (EXCEPT BASE) Pin Description Circuit 1-2 FUSED B(+) A114 18GY/RD 3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT 5 GROUND Z13 20BK/WT 6-- Component Location - 53 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12097 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12098 Power Distribution Module: Locations Module-Totally Integrated Power Component ID: 213 Component : MODULE-TOTALLY INTEGRATED POWER Connector: Name : MODULE-TOTALLY INTEGRATED POWER C1 Color : LT. GRAY # of pins : 14 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 2 TRS T41 SIGNAL (P/N) T41 18YL/DB 2 TRS T41 SIGNAL (P/N) T41 20YL/DB 2 STARTER SOLENOID CONTROL T752 20DG/OR 3-4 FUEL PUMP CONTROL K31 20BR 5 WIPER PARK SWITCH SENSE W7 20BR/GY 6-7-8 WASHER FLUID SWITCH RETURN G932 20VT/TN 9 WASHER FLUID SWITCH SENSE W1 20BR/TN 10 TRANSMISSION CONTROL T515 20YL/DB 11 HOOD AJAR SWITCH SENSE G70 20VT/LB 12 - 13 - 14 - Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12099 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12100 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C10 Color : LT. GRAY # of pins : 22 Pin Description Circuit 1 ASD CONTROL OUTPUT K342 16BR/WT 2 FUSED B(+) A405 18RD/DB 3 FUSED B(+) A941 18RD 4-5 FUSED B(+) A104 20YL/RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12101 6 FUSED B(+) A310 16RD/LB 7 REAR WINDOW DEFOGGER CONTROL OUTPUT C15 14DB/WT 8 FUSED IGNITION SWITCH OUTPUT (RUN-START) F12 14PK/RD 9 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 10 - 11 HORN CONTROL OUTPUT X22 18GY/LB 12 WIPER LOW SPEED CONTROL OUTPUT W3 18BR/WT 13 GROUND Z971 18BK 14 HEATED MIRROR CONTROL OUTPUT C16 18DB/GY 15 FUSED B(+) A212 20RD/OR 16 - - 17 FUSED B(+) A121 14RD/YL 18 FUEL PUMP CONTROL OUTPUT A109 16OR/RD 19 HORN CONTROL OUTPUT X21 18GY/YL 20 GROUND Z953 20BK 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 FUSED B(+) A400 14TN/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12102 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C2 Color : BLACK # of pins : 13 Pin Description Circuit 1-2 WASHER PUMP MOTOR CONTROL W10 20BR 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 ADJUSTABLE PEDALS OUTPUT A72 20RD/OR 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12103 6-7-8-9 FRONT AXLE LOCK CONTROL G304 20VT/DB 10 A/C CLUTCH CONTROL C13 20LB 10 A/C CLUTCH CONTROL C13 20LB/OR 11 ASD CONTROL K51 20BR/WT 12 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/OR 13 GROUND Z117 20BK/WT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12104 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C3 Color : BLACK # of pins : 22 Pin Description Circuit 1 FUSED B(+) A209 10RD 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F984 18PK/YL 4-5 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F983 20PK/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12105 6 FUSED B(+) A205 18RD/OR 7-8 FUSED B(+) A944 20RD 9 FUSED B(+) A116 16YL/RD 10 FUSED B(+) A118 18RD/OR 11 - 12 FUSED B(+) A918 20RD 12 FUSED B(+) A918 16RD 13 FUSED IGNITION SWITCH OUTPUT (RUN) F921 20PK/LB 14 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 15 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 16 FUSED B(+) A930 16RD 17 FUSED IGNITION SWITCH OUTPUT (RUN-START) F942 10PK/LG 18 TRAILER TOW LEFT TURN RELAY OUTPUTL673 18YL 19 TRAILER TOW RIGHT TURN RELAY OUTPUT L674 18LG 20 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 21 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 22 FUSED IGNITION SWITCH OUTPUT (RUN-START) F12 14PK/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12106 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C4 Color : LT. GRAY # of pins : 13 Pin Description Circuit 1 GROUND Z118 16BK/YL 2 SHIFT MOTOR CONTROL A T102 16YL 3 SHIFT MOTOR CONTROL B T101 16DG 4-5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12107 6-7-8 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 9 5 VOLT SUPPLY T103 20YL/OR 10 MODE SENSOR A D201 20WT/DG 11 SENSOR RETURN G180 20VT/YL 12 FUSED B(+) A880 20DB/RD 13 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12108 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C5 Color : BLACK # of pins : 10 Pin Description Circuit 1 LEFT FRONT TURN LAMP DRIVER L61 20WT/LG 2 RIGHT FRONT TURN LAMP DRIVER L60 20WT/TN 3 RIGHT HIGH BEAM DRIVER L34 20WT/GY 4 LEFT LOW BEAM DRIVER L43 20WT/DB 5 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12109 6-7-8 AAT SIGNAL G31 20VT/LG 9 AAT RETURN G930 20VT/TN 10 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12110 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C6 Color : BROWN # of pins : 16 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/LG 2 DIAGNOSTIC CAN C (+) D52 20WT/LB 3 CAN B BUS (+) D55 20WT/OR 4 LEFT REAR TURN LAMP DRIVER L63 20WT/DG 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12111 6 RIGHT REAR TURN LAMP DRIVER L62 20WT/YL 7 BRAKE LAMP SWITCH OUTPUT L50 20WT/TN 8-9 CAN C BUS (-) D64 20WT/LB 10 DIAGNOSTIC CAN C (-) D51 20WT/BR 11 CAN B BUS (-) D54 20WT 12 - 13 - 14 - 15 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 16 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12112 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C7 Color : BLUE # of pins : 14 Pin Description Circuit 1-2-3 RIGHT LOW BEAM DRIVER L44 20WT/TN 4 LEFT HIGH BEAM DRIVER L33 20WT/LG 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12113 6-7 A/C PRESSURE 5 VOLT SUPPLY C818 20LB/OR 8 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY 9-10 - 11 - 12 A/C PRESSURE SIGNAL C18 20LB/BR 13 A/C PRESSURE GROUND C918 20BK/LB 14 IGNITION START T751 20YL Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12114 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C8 Color : LT. GRAY # of pins : 12 Pin Description Circuit 1-2 FUSED B(+) A919 20RD 3 FUSED B(+) A106 20LB/RD 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 5 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20PK/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12115 6 FUSED B(+) A100 14RD/VT 7 FUSED B(+) A210 12OR/RD 8 FUSED B(+) A940 18RD 9 FUSED B(+) A103 18GY/RD 10 FOG LAMP CONTROL OUTPUT L89 18WT/YL 11 BACKUP LAMP FEED L1 18WT/LG 12 FUEL HEATER CONTROL OUTPUT A961 14RD 12 CONDENSER FAN CONTROL OUTPUT C123 12LB/WT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12116 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C9 Color : BLACK # of pins : 12 Pin Description Circuit 1 FUSED B(+) A111 16DG/RD 2 STARTER MOTOR CONTROL OUTPUT T750 14YL/GY 3 A/C CLUTCH CONTROL OUTPUT C3 20DB/YL 4 WIPER MOTOR HIGH SPEED FEED W4 16BR/OR 5 FUSED B(+) A114 18GY/RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12117 6 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 10PK/YL 7-8 FUSED PARK LAMP FEED L7 20WT/YL 9 FUSED PARK LAMP FEED L678 18BR 10 FUSED PARK LAMP FEED L70 20WT/GY 11 - 12 FUSED B(+) A107 12TN/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12118 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (DIESEL) Pin Description Circuit 1 B(+) A0 6RD Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12119 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12120 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (GAS) Pin Description Circuit 1 B(+) A11 8LB Pin Description Circuit 1 B(+) A0 6RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12121 Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12122 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12123 Power Distribution Module: Locations Auxiliary PDC Box Component ID: 22 Component : AUXILIARY PDC BOX Connector: Name : AUXILIARY PDC BOX Color : # of pins : 10 Qualifier : (UPFITTER PACKAGE) Pin Description Circuit 1 FUSED B(+) A420 10RD 2 3 FUSED B(+) A420 10RD 4 FUSED B(+) A422 14RD 5 FUSED B(+) A420 10RD 6 FUSED B(+) A423 14PK 7 8 FUSED IGNITION SWITCH OUTPUT (RUN) F922 16PK/RD 9 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 10 GROUND Z912 20BK Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12124 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead Power Distribution Module: Diagrams Module-Electronic Overhead Component ID: 202 Component : MODULE-ELECTRONIC OVERHEAD Connector: Name : MODULE-ELECTRONIC OVERHEAD Color : BLACK # of pins : 6 Qualifier : (EXCEPT BASE) Pin Description Circuit 1-2 FUSED B(+) A114 18GY/RD 3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT 5 GROUND Z13 20BK/WT 6-- Component Location - 53 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12127 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12128 Power Distribution Module: Diagrams Module-Totally Integrated Power Component ID: 213 Component : MODULE-TOTALLY INTEGRATED POWER Connector: Name : MODULE-TOTALLY INTEGRATED POWER C1 Color : LT. GRAY # of pins : 14 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 2 TRS T41 SIGNAL (P/N) T41 18YL/DB 2 TRS T41 SIGNAL (P/N) T41 20YL/DB 2 STARTER SOLENOID CONTROL T752 20DG/OR 3-4 FUEL PUMP CONTROL K31 20BR 5 WIPER PARK SWITCH SENSE W7 20BR/GY 6-7-8 WASHER FLUID SWITCH RETURN G932 20VT/TN 9 WASHER FLUID SWITCH SENSE W1 20BR/TN 10 TRANSMISSION CONTROL T515 20YL/DB 11 HOOD AJAR SWITCH SENSE G70 20VT/LB 12 - 13 - 14 - Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12129 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12130 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C10 Color : LT. GRAY # of pins : 22 Pin Description Circuit 1 ASD CONTROL OUTPUT K342 16BR/WT 2 FUSED B(+) A405 18RD/DB 3 FUSED B(+) A941 18RD 4-5 FUSED B(+) A104 20YL/RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12131 6 FUSED B(+) A310 16RD/LB 7 REAR WINDOW DEFOGGER CONTROL OUTPUT C15 14DB/WT 8 FUSED IGNITION SWITCH OUTPUT (RUN-START) F12 14PK/RD 9 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 10 - 11 HORN CONTROL OUTPUT X22 18GY/LB 12 WIPER LOW SPEED CONTROL OUTPUT W3 18BR/WT 13 GROUND Z971 18BK 14 HEATED MIRROR CONTROL OUTPUT C16 18DB/GY 15 FUSED B(+) A212 20RD/OR 16 - - 17 FUSED B(+) A121 14RD/YL 18 FUEL PUMP CONTROL OUTPUT A109 16OR/RD 19 HORN CONTROL OUTPUT X21 18GY/YL 20 GROUND Z953 20BK 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 FUSED B(+) A400 14TN/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12132 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C2 Color : BLACK # of pins : 13 Pin Description Circuit 1-2 WASHER PUMP MOTOR CONTROL W10 20BR 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 ADJUSTABLE PEDALS OUTPUT A72 20RD/OR 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12133 6-7-8-9 FRONT AXLE LOCK CONTROL G304 20VT/DB 10 A/C CLUTCH CONTROL C13 20LB 10 A/C CLUTCH CONTROL C13 20LB/OR 11 ASD CONTROL K51 20BR/WT 12 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/OR 13 GROUND Z117 20BK/WT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12134 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C3 Color : BLACK # of pins : 22 Pin Description Circuit 1 FUSED B(+) A209 10RD 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F984 18PK/YL 4-5 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F983 20PK/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12135 6 FUSED B(+) A205 18RD/OR 7-8 FUSED B(+) A944 20RD 9 FUSED B(+) A116 16YL/RD 10 FUSED B(+) A118 18RD/OR 11 - 12 FUSED B(+) A918 20RD 12 FUSED B(+) A918 16RD 13 FUSED IGNITION SWITCH OUTPUT (RUN) F921 20PK/LB 14 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 15 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 16 FUSED B(+) A930 16RD 17 FUSED IGNITION SWITCH OUTPUT (RUN-START) F942 10PK/LG 18 TRAILER TOW LEFT TURN RELAY OUTPUTL673 18YL 19 TRAILER TOW RIGHT TURN RELAY OUTPUT L674 18LG 20 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 21 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 22 FUSED IGNITION SWITCH OUTPUT (RUN-START) F12 14PK/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12136 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C4 Color : LT. GRAY # of pins : 13 Pin Description Circuit 1 GROUND Z118 16BK/YL 2 SHIFT MOTOR CONTROL A T102 16YL 3 SHIFT MOTOR CONTROL B T101 16DG 4-5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12137 6-7-8 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 9 5 VOLT SUPPLY T103 20YL/OR 10 MODE SENSOR A D201 20WT/DG 11 SENSOR RETURN G180 20VT/YL 12 FUSED B(+) A880 20DB/RD 13 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12138 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C5 Color : BLACK # of pins : 10 Pin Description Circuit 1 LEFT FRONT TURN LAMP DRIVER L61 20WT/LG 2 RIGHT FRONT TURN LAMP DRIVER L60 20WT/TN 3 RIGHT HIGH BEAM DRIVER L34 20WT/GY 4 LEFT LOW BEAM DRIVER L43 20WT/DB 5 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12139 6-7-8 AAT SIGNAL G31 20VT/LG 9 AAT RETURN G930 20VT/TN 10 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12140 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C6 Color : BROWN # of pins : 16 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/LG 2 DIAGNOSTIC CAN C (+) D52 20WT/LB 3 CAN B BUS (+) D55 20WT/OR 4 LEFT REAR TURN LAMP DRIVER L63 20WT/DG 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12141 6 RIGHT REAR TURN LAMP DRIVER L62 20WT/YL 7 BRAKE LAMP SWITCH OUTPUT L50 20WT/TN 8-9 CAN C BUS (-) D64 20WT/LB 10 DIAGNOSTIC CAN C (-) D51 20WT/BR 11 CAN B BUS (-) D54 20WT 12 - 13 - 14 - 15 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 16 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12142 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C7 Color : BLUE # of pins : 14 Pin Description Circuit 1-2-3 RIGHT LOW BEAM DRIVER L44 20WT/TN 4 LEFT HIGH BEAM DRIVER L33 20WT/LG 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12143 6-7 A/C PRESSURE 5 VOLT SUPPLY C818 20LB/OR 8 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY 9-10 - 11 - 12 A/C PRESSURE SIGNAL C18 20LB/BR 13 A/C PRESSURE GROUND C918 20BK/LB 14 IGNITION START T751 20YL Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12144 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C8 Color : LT. GRAY # of pins : 12 Pin Description Circuit 1-2 FUSED B(+) A919 20RD 3 FUSED B(+) A106 20LB/RD 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 5 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20PK/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12145 6 FUSED B(+) A100 14RD/VT 7 FUSED B(+) A210 12OR/RD 8 FUSED B(+) A940 18RD 9 FUSED B(+) A103 18GY/RD 10 FOG LAMP CONTROL OUTPUT L89 18WT/YL 11 BACKUP LAMP FEED L1 18WT/LG 12 FUEL HEATER CONTROL OUTPUT A961 14RD 12 CONDENSER FAN CONTROL OUTPUT C123 12LB/WT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12146 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C9 Color : BLACK # of pins : 12 Pin Description Circuit 1 FUSED B(+) A111 16DG/RD 2 STARTER MOTOR CONTROL OUTPUT T750 14YL/GY 3 A/C CLUTCH CONTROL OUTPUT C3 20DB/YL 4 WIPER MOTOR HIGH SPEED FEED W4 16BR/OR 5 FUSED B(+) A114 18GY/RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12147 6 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 10PK/YL 7-8 FUSED PARK LAMP FEED L7 20WT/YL 9 FUSED PARK LAMP FEED L678 18BR 10 FUSED PARK LAMP FEED L70 20WT/GY 11 - 12 FUSED B(+) A107 12TN/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12148 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (DIESEL) Pin Description Circuit 1 B(+) A0 6RD Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12149 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12150 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (GAS) Pin Description Circuit 1 B(+) A11 8LB Pin Description Circuit 1 B(+) A0 6RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12151 Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12152 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12153 Power Distribution Module: Diagrams Auxiliary PDC Box Component ID: 22 Component : AUXILIARY PDC BOX Connector: Name : AUXILIARY PDC BOX Color : # of pins : 10 Qualifier : (UPFITTER PACKAGE) Pin Description Circuit 1 FUSED B(+) A420 10RD 2 3 FUSED B(+) A420 10RD 4 FUSED B(+) A422 14RD 5 FUSED B(+) A420 10RD 6 FUSED B(+) A423 14PK 7 8 FUSED IGNITION SWITCH OUTPUT (RUN) F922 16PK/RD 9 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 10 GROUND Z912 20BK Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12154 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Description Power Distribution Module: Description and Operation Description DESCRIPTION The Totally Integrated Power Module (2)(TIPM) is a combination unit that performs the functions of the Power Distribution Center (PDC) and the Front Control Module. The TIPM is a printed circuit board based module that contains fuses, internal relays and a microprocessor that performs the functions previously executed by the FCM. The TIPM (2) is located in the engine compartment, next to the battery (1) and connects directly to the B+ cable (5) via a stud located on top of the unit. The ground connection is via electrical connectors. The TIPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic TIPM housing includes a base and cover. The TIPM cover is easily opened or removed for service and has a fuse and relay layout map integral to the inside surface of the cover. The TIPM housing base and cover are secured in place via mounting tabs. The mounting tabs secure the TIPM (2) to the battery tray mounting bracket (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Description > Page 12157 Power Distribution Module: Description and Operation Operation OPERATION All of the current from the battery and the generator output enters the Totally Integrated Power Module (TIPM) via a stud on the top of the module. The TIPM cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal Power Distribution Module: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the B+ terminal nut (6) from the Totally Integrated Power Module (2)(TIPM) B+ terminal. Remove the B+ cable (5) from the TIPM (2). 3. Using a suitable flat blade tool, disengage the TIPM (2) upper retaining tabs from the battery tray bracket (3). 4. Grasp the TIPM (1) and rotate the assembly up to free it from its mounting bracket (3). Position the assembly upside down to access the electrical connectors located on the bottom of the unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal > Page 12160 5. Disconnect the electrical connectors (2) by depressing the locking tab and rotating the connector arm outboard, until the connector is free from the TIPM assembly (1). Be certain to pull the connectors straight off. 6. Remove the TIPM (1) from the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal > Page 12161 Power Distribution Module: Service and Repair Installation INSTALLATION 1. Position the Totally Integrated Power Module (1)(TIPM) into the vehicle. NOTE: Totally Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors (2) by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the TIPM assembly (1). 3. Turn the TIPM (1) so that the connector side is facing down. Install the assembly onto the TIPM battery tray bracket (3) making sure to line up the lower retaining tab with the retaining slot in the tray (1). 4. Push the TIPM (1) downward to lock the upper retaining clips into the bracket (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal > Page 12162 5. Install the B+ terminal cable (5) and nut (6) on the B+ terminal of the TIPM (2). 6. Connect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) Relay Box: Locations Fuses (Integrated Power Module) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) > Page 12167 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) > Page 12168 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) > Page 12169 Relay Box: Locations Auxiliary PDC Box (Upfitter Package) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) Relay Box: Application and ID Fuses (Integrated Power Module) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 12172 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 12173 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 12174 Relay Box: Application and ID Auxiliary PDC Box (Upfitter Package) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) Relay Box: Locations Fuses (Integrated Power Module) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) > Page 12179 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) > Page 12180 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) > Page 12181 Relay Box: Locations Auxiliary PDC Box (Upfitter Package) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) Relay Box: Application and ID Fuses (Integrated Power Module) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 12184 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 12185 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 12186 Relay Box: Application and ID Auxiliary PDC Box (Upfitter Package) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations Auxiliary Power Outlet: Locations Component ID: 234 Component : POWER OUTLET Connector: Name : POWER OUTLET Color : GRAY # of pins : 3 Pin Description Circuit 1 FUSED B(+) A205 18RD/OR 2-3 GROUND Z737 18BK/LB Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Page 12191 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12194 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12195 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12196 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12197 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12198 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12199 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12200 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12201 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12202 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12203 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12204 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12205 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12206 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12207 Auxiliary Power Outlet: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12208 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12209 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12210 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12211 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12212 Auxiliary Power Outlet: Connector Views Power Outlet Component ID: 234 Component : POWER OUTLET Connector: Name : POWER OUTLET Color : GRAY # of pins : 3 Pin Description Circuit 1 FUSED B(+) A205 18RD/OR 2-3 GROUND Z737 18BK/LB Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12213 Power Outlet-Console Component ID: 235 Component : POWER OUTLET-CONSOLE Connector: Name : POWER OUTLET-CONSOLE Color : GRAY # of pins : 3 Pin Description Circuit Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12214 1 FUSED B(+) A405 18BR Pin Description Circuit 1 FUSED B(+) A405 18RD/DB 2-3 GROUND Z939 18BK Power Outlet-Lower Console Component ID: 236 Component : POWER OUTLET-LOWER CONSOLE Connector: Name : POWER OUTLET-LOWER CONSOLE Color : # of pins : 3 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F984 16PK/YL 2-- 3 GROUND Z939 18BK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12215 Auxiliary Power Outlet: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-41-02 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12216 8w-41-03 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 12217 8w-41-04 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Power Outlet-Instrument Panel Auxiliary Power Outlet: Description and Operation Power Outlet-Instrument Panel Description DESCRIPTION A cigar lighter outlet is installed to the left of the center stack area in the lower instrument panel. The cigar lighter outlet is secured by a snap fit within the bezel. The cigar lighter outlet, plastic cap and the knob and heating element unit are available for service replacement. These components cannot be repaired and, if inoperative or damaged, they must be replaced. Operation OPERATION The cigar lighter consists of two major components: a knob and heating element unit, and the cigar lighter base or outlet shell. The receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The cigar lighter receives battery voltage from a fuse in the Integrated Power Module (IPM) when the ignition switch is in the Accessory or Run positions. The cigar lighter knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating element are inserted in the outlet shell, the heating element resistor coil is grounded through its housing to the outlet shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating element, and the heating element extends from the housing toward the insulated contact in the bottom of the outlet shell. Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the outlet shell. These clips engage and hold the heating element against the insulated contact long enough for the resistor coil to heat up. When the heating element is engaged with the contact, battery current can flow through the resistor coil to ground, causing the resistor coil to heat. When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating element, the spring-loaded housing forces the knob and heating element to pop back outward to their relaxed position. When the cigar lighter knob and element are pulled out of the outlet shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Power Outlet-Instrument Panel > Page 12220 Auxiliary Power Outlet: Description and Operation Power Outlet-Console Description DESCRIPTION Two power outlets are utilized on this model. One in the instrument panel center lower bezel and the other in the center console. The power outlet bases are secured by a snap fit within the instrument panel or trim panel. A plastic protective cap snaps into the power outlet base when the power outlet is not being used, and hangs from the power outlet base mount by an integral bail strap while the power outlet is in use. The power outlet receptacle unit and the accessory power outlet protective cap are available for service. The power outlet receptacle cannot be repaired and, if faulty or damaged, it must be replaced. Operation OPERATION The power outlet base or receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet receives battery voltage from a fuse in the integrated power module at all times. While the power outlet is very similar to a cigar lighter base unit, it does not include the two small spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar lighter heating element to the insulated contact. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Cigar Lighter Outlet Auxiliary Power Outlet: Testing and Inspection Cigar Lighter Outlet CIGAR LIGHTER OUTLET For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Check the fused B(+) fuse in the Integrated Power Module (IPM). If OK, go to STEP 2. If not OK, repair the shorted circuit or component as required and replace the inoperative fuse. 2. Turn the ignition switch to the Run position. Check for battery voltage at the fused B(+) fuse in the IPM. If OK, go to STEP 3. If not OK, repair the open or short as required. 3. Remove the cigar lighter knob and element from the cigar lighter outlet shell. Check for continuity between the inside circumference of the cigar lighter outlet shell and a good ground. there should be continuity. If OK, go to STEP 4. If not OK, go to STEP 5. 4. Turn the ignition switch to the Run position. Check for battery voltage at the insulated contact located at the back of the cigar lighter outlet shell. If OK, replace the inoperative cigar lighter knob and element. If not OK, go to STEP 5. 5. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Check for continuity between the ground circuit cavity of the cigar lighter wire harness connector and a good ground. There should be continuity. If OK, go to STEP 6. If not OK, repair the open ground circuit to ground as required. 6. Connect the battery negative cable. Turn the ignition switch to the Accessory or Run positions. Check for battery voltage at the fused B(+) circuit cavity of the cigar lighter wire harness connector. If OK, replace the inoperative cigar lighter outlet. If not OK, repair the open fused B(+) circuit to the IPM fuse as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Cigar Lighter Outlet > Page 12223 Auxiliary Power Outlet: Testing and Inspection Power Outlet POWER OUTLET For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Check the fused B(+) fuse in the Integrated Power Module (IPM). If OK, go to STEP 2. If not OK, repair the shorted circuit or component as required and replace the inoperative fuse. 2. Turn the ignition switch to the Run position. Check for battery voltage at the fused B(+) fuse in the IPM. If OK, go to STEP 3. If not OK, repair the open or short as required. 3. Remove the cigar lighter knob and element from the cigar lighter outlet shell. Check for continuity between the inside circumference of the cigar lighter outlet shell and a good ground. there should be continuity. If OK, go to STEP 4. If not OK, go to STEP 5. 4. Turn the ignition switch to the Run position. Check for battery voltage at the insulated contact located at the back of the cigar lighter outlet shell. If OK, replace the inoperative cigar lighter knob and element. If not OK, go to STEP 5. 5. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Check for continuity between the ground circuit cavity of the cigar lighter wire harness connector and a good ground. There should be continuity. If OK, go to STEP 6. If not OK, repair the open ground circuit to ground as required. 6. Connect the battery negative cable. Turn the ignition switch to the Accessory or Run positions. Check for battery voltage at the fused B(+) circuit cavity of the cigar lighter wire harness connector. If OK, replace the inoperative cigar lighter outlet. If not OK, repair the open fused B(+) circuit to the IPM fuse as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Power Outlet-Instrument Panel Auxiliary Power Outlet: Service and Repair Power Outlet-Instrument Panel Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Pull the cigar lighter knob and element (1) out of the cigar lighter receptacle base (6), or unsnap the protective cap from the power outlet receptacle base (6). 3. Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangular retaining bosses (3) of the mount that secures the receptacle base to the panel (4). 4. Insert a pair of external snap ring pliers (5) into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 5. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount. 6. Pull the receptacle base away from the instrument panel far enough to access the instrument panel wire harness connector (2). 7. Disconnect the instrument panel wire harness connector (2) from the cigar lighter or power outlet receptacle base (6). 8. Remove the cigar lighter or power outlet mount from the instrument panel. Installation INSTALLATION 1. Connect the instrument panel wire harness connector to the cigar lighter or power outlet receptacle base connector receptacle. 2. Install the cigar lighter or power outlet mount into the instrument panel. 3. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 4. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 5. Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base. 6. Connect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Power Outlet-Instrument Panel > Page 12226 Auxiliary Power Outlet: Service and Repair Power Outlet-Console Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Pull the cigar lighter knob and element (1) out of the cigar lighter receptacle base (6), or unsnap the protective cap from the power outlet receptacle base (6). 3. Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangular retaining bosses (3) of the mount that secures the receptacle base to the panel (4). 4. Insert a pair of external snap ring pliers (5) into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 5. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount. 6. Pull the receptacle base away from the instrument panel far enough to access the instrument panel wire harness connector (2). 7. Disconnect the instrument panel wire harness connector (2) from the cigar lighter or power outlet receptacle base (6). 8. Remove the cigar lighter or power outlet mount from the instrument panel. Installation INSTALLATION 1. Connect the instrument panel wire harness connector to the cigar lighter or power outlet receptacle base connector receptacle. 2. Install the cigar lighter or power outlet mount into the instrument panel. 3. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 4. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 5. Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base. 6. Connect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations Electrical Accessory Panel: Locations Component ID: 233 Component : PORT-UPFITTERS Connector: Name : PORT-UPFITTERS Color : # of pins : 10 Pin Description Circuit 1 PTO SENSE G113 18PK/YL Pin Description Circuit 1 RUN RELAY OUTPUT F923 16PK/YL Pin Description Circuit 1 IN CAB POWER TAKEOFF SWITCH INPUT K425 16PK/YL 2 S/C SWITCH RETURN V937 18VT/BR 3 POWER TAKEOFF SYSTEM STATUS BULB G425 18VT/YL 4 FUSED IGNITION SWITCH OUTPUT (RUN) F922 16PK/RD 5 FUSED B(+) A423 14PK 6 FUSED B(+) A423 14PK 7 FUSED B(+) A422 14RD 8 FUSED B(+) A422 14RD 9 FUSED B(+) A426 14VT 10 - Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 12230 Connector: Name : PORT-UPFITTERS Color : # of pins : 10 Pin Description Circuit 1 RUN RELAY OUTPUT F923 16PK/YL 2 S/C SWITCH RETURN V937 18VT/BR 3 POWER TAKEOFF SYSTEM STATUS BULB G425 18VT/YL 4 FUSED IGNITION SWITCH OUTPUT (RUN) F922 16PK/RD 5 FUSED B(+) A423 14PK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 12231 6 FUSED B(+) A423 14PK 7 FUSED B(+) A422 14RD 8 FUSED B(+) A422 14RD 9 FUSED B(+) A426 14VT 10 - Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 12232 Electrical Accessory Panel: Diagrams Component ID: 233 Component : PORT-UPFITTERS Connector: Name : PORT-UPFITTERS Color : # of pins : 10 Pin Description Circuit 1 PTO SENSE G113 18PK/YL Pin Description Circuit 1 RUN RELAY OUTPUT F923 16PK/YL Pin Description Circuit 1 IN CAB POWER TAKEOFF SWITCH INPUT K425 16PK/YL 2 S/C SWITCH RETURN V937 18VT/BR 3 POWER TAKEOFF SYSTEM STATUS BULB G425 18VT/YL 4 FUSED IGNITION SWITCH OUTPUT (RUN) F922 16PK/RD 5 FUSED B(+) A423 14PK 6 FUSED B(+) A423 14PK 7 FUSED B(+) A422 14RD 8 FUSED B(+) A422 14RD 9 FUSED B(+) A426 14VT 10 - Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 12233 Connector: Name : PORT-UPFITTERS Color : # of pins : 10 Pin Description Circuit 1 RUN RELAY OUTPUT F923 16PK/YL 2 S/C SWITCH RETURN V937 18VT/BR 3 POWER TAKEOFF SYSTEM STATUS BULB G425 18VT/YL 4 FUSED IGNITION SWITCH OUTPUT (RUN) F922 16PK/RD 5 FUSED B(+) A423 14PK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 12234 6 FUSED B(+) A423 14PK 7 FUSED B(+) A422 14RD 8 FUSED B(+) A422 14RD 9 FUSED B(+) A426 14VT 10 - Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation Fuse: Customer Interest Electrical Systems - Intermittent Component Operation NUMBER:08-016-06 REV. A GROUP: Electrical DATE: July 18, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-016-06, DATED MARCH 22, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF A VEHICLE BODY STYLE. SUBJECT: Intermittent Operation Of Electrical Components Due To Ignition Off Draw (IOD) Fuse Not Being Fully Seated MODELS: 2007 (PM) Caliber **2007 (MK-49) Compass** 2006 - 2007 (DHIDRID1) Ram Truck 2006 - 2007 (PT) Chrysler PT Cruiser DISCUSSION: The Ignition Off Draw (IOD) fuse is used to prevent battery discharge during shipping and long term storage of the vehicles. The IOD fuse is located in the Total Integrated Power Module (TI PM). If the fuse is not completely inserted partial contact of the fuse terminals could occur. When the vehicle is prepped for customer delivery, ensure that the fuse is fully engaged (Fig. 1). The IOD fuse must also be fully released to prevent battery drain from occurring when the vehicle is stored. When the IOD fuse holder is depressed into the carrier, an initial distinct detent will be felt to overcome the "pre-hold position". You must then continue to push straight down on the IOD pre-holder until no further downward movement is encountered. NOTE: If the fuse is not pushed down symmetrically, two detents MAY be felt as each side snaps past the pre-hold position. Push down until no further downward movement is encountered. On 2006 and 2007 PT and PM vehicles the circuits fed by the IOD fuse are: Radio, Security module & siren (BUX), Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Power Mirrors, Clock, Memory Seat, Amplifier, CCN wake-up with ignition off and Homelink. On 2006 and 2007 DR, DH or D1 vehicles the circuits fed by the IOD fuse are: Radio, EVIC, Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Video Screen, CCN wake-up with ignition off, Underhood Lamp, CCN Interior Lighting Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation > Page 12243 POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation Fuse: All Technical Service Bulletins Electrical Systems - Intermittent Component Operation NUMBER:08-016-06 REV. A GROUP: Electrical DATE: July 18, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-016-06, DATED MARCH 22, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF A VEHICLE BODY STYLE. SUBJECT: Intermittent Operation Of Electrical Components Due To Ignition Off Draw (IOD) Fuse Not Being Fully Seated MODELS: 2007 (PM) Caliber **2007 (MK-49) Compass** 2006 - 2007 (DHIDRID1) Ram Truck 2006 - 2007 (PT) Chrysler PT Cruiser DISCUSSION: The Ignition Off Draw (IOD) fuse is used to prevent battery discharge during shipping and long term storage of the vehicles. The IOD fuse is located in the Total Integrated Power Module (TI PM). If the fuse is not completely inserted partial contact of the fuse terminals could occur. When the vehicle is prepped for customer delivery, ensure that the fuse is fully engaged (Fig. 1). The IOD fuse must also be fully released to prevent battery drain from occurring when the vehicle is stored. When the IOD fuse holder is depressed into the carrier, an initial distinct detent will be felt to overcome the "pre-hold position". You must then continue to push straight down on the IOD pre-holder until no further downward movement is encountered. NOTE: If the fuse is not pushed down symmetrically, two detents MAY be felt as each side snaps past the pre-hold position. Push down until no further downward movement is encountered. On 2006 and 2007 PT and PM vehicles the circuits fed by the IOD fuse are: Radio, Security module & siren (BUX), Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Power Mirrors, Clock, Memory Seat, Amplifier, CCN wake-up with ignition off and Homelink. On 2006 and 2007 DR, DH or D1 vehicles the circuits fed by the IOD fuse are: Radio, EVIC, Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Video Screen, CCN wake-up with ignition off, Underhood Lamp, CCN Interior Lighting Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation > Page 12249 POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses (Integrated Power Module) Fuse: Locations Fuses (Integrated Power Module) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses (Integrated Power Module) > Page 12252 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses (Integrated Power Module) > Page 12253 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses (Integrated Power Module) > Page 12254 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses (Integrated Power Module) > Page 12255 Fuse: Locations Auxiliary PDC Box (Upfitter Package) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 12258 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 12259 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 12260 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 12261 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 12262 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 12263 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 12264 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 12265 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 12266 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 12267 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 12268 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 12269 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 12270 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 12271 Fuse: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 12272 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 12273 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 12274 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 12275 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses (Integrated Power Module) Fuse: Application and ID Fuses (Integrated Power Module) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 12278 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 12279 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 12280 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 12281 Fuse: Application and ID Auxiliary PDC Box (Upfitter Package) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Description and Operation > Description Fuse: Description and Operation Description DESCRIPTION All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Totally Integrated Power Module (TIPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the TIPM as part of the new vehicle preparation procedures and then disconnect it again until new vehicle delivery to the customer. A laser printed fuse layout map is integral to the TIPM cover to ensure proper fuse identification. The IOD fuse is a 20 ampere mini blade-type fuse. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in the TIPM cavity, and as a fuse holder that conveniently stores the fuse in the same cavity after it has been disconnected. CIRCUITS INCLUDED WITH IOD FUSE - Cluster (CCN) - Diagnostic Connector - Map Lamps - Glove Box Lamp - Courtesy Lamps - Radio - Underhood Lamp Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Description and Operation > Description > Page 12284 Fuse: Description and Operation Operation OPERATION The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from Integrated Power Module (IPM) fuse cavity # 51 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses (Integrated Power Module) Fuse Block: Locations Fuses (Integrated Power Module) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses (Integrated Power Module) > Page 12289 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses (Integrated Power Module) > Page 12290 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses (Integrated Power Module) > Page 12291 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses (Integrated Power Module) > Page 12292 Fuse Block: Locations Auxiliary PDC Box (Upfitter Package) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 12295 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 12296 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 12297 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 12298 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 12299 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 12300 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 12301 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 12302 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 12303 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 12304 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 12305 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 12306 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 12307 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 12308 Fuse Block: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 12309 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 12310 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 12311 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 12312 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses (Integrated Power Module) Fuse Block: Application and ID Fuses (Integrated Power Module) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 12315 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 12316 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 12317 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 12318 Fuse Block: Application and ID Auxiliary PDC Box (Upfitter Package) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Power Distribution Module: Customer Interest Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 12327 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 12328 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 12329 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 12330 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System Engine No Crank/No Start Condition Power Distribution Module: Customer Interest Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System Engine No Crank/No Start Condition > Page 12335 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System Engine No Crank/No Start Condition > Page 12336 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System Engine No Crank/No Start Condition > Page 12337 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System Engine No Crank/No Start Condition > Page 12338 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Power Distribution Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 12344 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 12345 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 12346 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 12347 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: All Technical Service Bulletins Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12352 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12353 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12354 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12355 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead Power Distribution Module: Locations Module-Electronic Overhead Component ID: 202 Component : MODULE-ELECTRONIC OVERHEAD Connector: Name : MODULE-ELECTRONIC OVERHEAD Color : BLACK # of pins : 6 Qualifier : (EXCEPT BASE) Pin Description Circuit 1-2 FUSED B(+) A114 18GY/RD 3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT 5 GROUND Z13 20BK/WT 6-- Component Location - 53 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12358 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12359 Power Distribution Module: Locations Module-Totally Integrated Power Component ID: 213 Component : MODULE-TOTALLY INTEGRATED POWER Connector: Name : MODULE-TOTALLY INTEGRATED POWER C1 Color : LT. GRAY # of pins : 14 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 2 TRS T41 SIGNAL (P/N) T41 18YL/DB 2 TRS T41 SIGNAL (P/N) T41 20YL/DB 2 STARTER SOLENOID CONTROL T752 20DG/OR 3-4 FUEL PUMP CONTROL K31 20BR 5 WIPER PARK SWITCH SENSE W7 20BR/GY 6-7-8 WASHER FLUID SWITCH RETURN G932 20VT/TN 9 WASHER FLUID SWITCH SENSE W1 20BR/TN 10 TRANSMISSION CONTROL T515 20YL/DB 11 HOOD AJAR SWITCH SENSE G70 20VT/LB 12 - 13 - 14 - Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12360 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12361 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C10 Color : LT. GRAY # of pins : 22 Pin Description Circuit 1 ASD CONTROL OUTPUT K342 16BR/WT 2 FUSED B(+) A405 18RD/DB 3 FUSED B(+) A941 18RD 4-5 FUSED B(+) A104 20YL/RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12362 6 FUSED B(+) A310 16RD/LB 7 REAR WINDOW DEFOGGER CONTROL OUTPUT C15 14DB/WT 8 FUSED IGNITION SWITCH OUTPUT (RUN-START) F12 14PK/RD 9 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 10 - 11 HORN CONTROL OUTPUT X22 18GY/LB 12 WIPER LOW SPEED CONTROL OUTPUT W3 18BR/WT 13 GROUND Z971 18BK 14 HEATED MIRROR CONTROL OUTPUT C16 18DB/GY 15 FUSED B(+) A212 20RD/OR 16 - - 17 FUSED B(+) A121 14RD/YL 18 FUEL PUMP CONTROL OUTPUT A109 16OR/RD 19 HORN CONTROL OUTPUT X21 18GY/YL 20 GROUND Z953 20BK 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 FUSED B(+) A400 14TN/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12363 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C2 Color : BLACK # of pins : 13 Pin Description Circuit 1-2 WASHER PUMP MOTOR CONTROL W10 20BR 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 ADJUSTABLE PEDALS OUTPUT A72 20RD/OR 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12364 6-7-8-9 FRONT AXLE LOCK CONTROL G304 20VT/DB 10 A/C CLUTCH CONTROL C13 20LB 10 A/C CLUTCH CONTROL C13 20LB/OR 11 ASD CONTROL K51 20BR/WT 12 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/OR 13 GROUND Z117 20BK/WT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12365 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C3 Color : BLACK # of pins : 22 Pin Description Circuit 1 FUSED B(+) A209 10RD 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F984 18PK/YL 4-5 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F983 20PK/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12366 6 FUSED B(+) A205 18RD/OR 7-8 FUSED B(+) A944 20RD 9 FUSED B(+) A116 16YL/RD 10 FUSED B(+) A118 18RD/OR 11 - 12 FUSED B(+) A918 20RD 12 FUSED B(+) A918 16RD 13 FUSED IGNITION SWITCH OUTPUT (RUN) F921 20PK/LB 14 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 15 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 16 FUSED B(+) A930 16RD 17 FUSED IGNITION SWITCH OUTPUT (RUN-START) F942 10PK/LG 18 TRAILER TOW LEFT TURN RELAY OUTPUTL673 18YL 19 TRAILER TOW RIGHT TURN RELAY OUTPUT L674 18LG 20 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 21 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 22 FUSED IGNITION SWITCH OUTPUT (RUN-START) F12 14PK/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12367 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C4 Color : LT. GRAY # of pins : 13 Pin Description Circuit 1 GROUND Z118 16BK/YL 2 SHIFT MOTOR CONTROL A T102 16YL 3 SHIFT MOTOR CONTROL B T101 16DG 4-5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12368 6-7-8 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 9 5 VOLT SUPPLY T103 20YL/OR 10 MODE SENSOR A D201 20WT/DG 11 SENSOR RETURN G180 20VT/YL 12 FUSED B(+) A880 20DB/RD 13 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12369 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C5 Color : BLACK # of pins : 10 Pin Description Circuit 1 LEFT FRONT TURN LAMP DRIVER L61 20WT/LG 2 RIGHT FRONT TURN LAMP DRIVER L60 20WT/TN 3 RIGHT HIGH BEAM DRIVER L34 20WT/GY 4 LEFT LOW BEAM DRIVER L43 20WT/DB 5 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12370 6-7-8 AAT SIGNAL G31 20VT/LG 9 AAT RETURN G930 20VT/TN 10 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12371 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C6 Color : BROWN # of pins : 16 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/LG 2 DIAGNOSTIC CAN C (+) D52 20WT/LB 3 CAN B BUS (+) D55 20WT/OR 4 LEFT REAR TURN LAMP DRIVER L63 20WT/DG 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12372 6 RIGHT REAR TURN LAMP DRIVER L62 20WT/YL 7 BRAKE LAMP SWITCH OUTPUT L50 20WT/TN 8-9 CAN C BUS (-) D64 20WT/LB 10 DIAGNOSTIC CAN C (-) D51 20WT/BR 11 CAN B BUS (-) D54 20WT 12 - 13 - 14 - 15 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 16 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12373 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C7 Color : BLUE # of pins : 14 Pin Description Circuit 1-2-3 RIGHT LOW BEAM DRIVER L44 20WT/TN 4 LEFT HIGH BEAM DRIVER L33 20WT/LG 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12374 6-7 A/C PRESSURE 5 VOLT SUPPLY C818 20LB/OR 8 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY 9-10 - 11 - 12 A/C PRESSURE SIGNAL C18 20LB/BR 13 A/C PRESSURE GROUND C918 20BK/LB 14 IGNITION START T751 20YL Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12375 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C8 Color : LT. GRAY # of pins : 12 Pin Description Circuit 1-2 FUSED B(+) A919 20RD 3 FUSED B(+) A106 20LB/RD 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 5 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20PK/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12376 6 FUSED B(+) A100 14RD/VT 7 FUSED B(+) A210 12OR/RD 8 FUSED B(+) A940 18RD 9 FUSED B(+) A103 18GY/RD 10 FOG LAMP CONTROL OUTPUT L89 18WT/YL 11 BACKUP LAMP FEED L1 18WT/LG 12 FUEL HEATER CONTROL OUTPUT A961 14RD 12 CONDENSER FAN CONTROL OUTPUT C123 12LB/WT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12377 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C9 Color : BLACK # of pins : 12 Pin Description Circuit 1 FUSED B(+) A111 16DG/RD 2 STARTER MOTOR CONTROL OUTPUT T750 14YL/GY 3 A/C CLUTCH CONTROL OUTPUT C3 20DB/YL 4 WIPER MOTOR HIGH SPEED FEED W4 16BR/OR 5 FUSED B(+) A114 18GY/RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12378 6 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 10PK/YL 7-8 FUSED PARK LAMP FEED L7 20WT/YL 9 FUSED PARK LAMP FEED L678 18BR 10 FUSED PARK LAMP FEED L70 20WT/GY 11 - 12 FUSED B(+) A107 12TN/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12379 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (DIESEL) Pin Description Circuit 1 B(+) A0 6RD Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12380 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12381 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (GAS) Pin Description Circuit 1 B(+) A11 8LB Pin Description Circuit 1 B(+) A0 6RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12382 Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12383 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12384 Power Distribution Module: Locations Auxiliary PDC Box Component ID: 22 Component : AUXILIARY PDC BOX Connector: Name : AUXILIARY PDC BOX Color : # of pins : 10 Qualifier : (UPFITTER PACKAGE) Pin Description Circuit 1 FUSED B(+) A420 10RD 2 3 FUSED B(+) A420 10RD 4 FUSED B(+) A422 14RD 5 FUSED B(+) A420 10RD 6 FUSED B(+) A423 14PK 7 8 FUSED IGNITION SWITCH OUTPUT (RUN) F922 16PK/RD 9 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 10 GROUND Z912 20BK Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12385 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead Power Distribution Module: Diagrams Module-Electronic Overhead Component ID: 202 Component : MODULE-ELECTRONIC OVERHEAD Connector: Name : MODULE-ELECTRONIC OVERHEAD Color : BLACK # of pins : 6 Qualifier : (EXCEPT BASE) Pin Description Circuit 1-2 FUSED B(+) A114 18GY/RD 3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT 5 GROUND Z13 20BK/WT 6-- Component Location - 53 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12388 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12389 Power Distribution Module: Diagrams Module-Totally Integrated Power Component ID: 213 Component : MODULE-TOTALLY INTEGRATED POWER Connector: Name : MODULE-TOTALLY INTEGRATED POWER C1 Color : LT. GRAY # of pins : 14 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 2 TRS T41 SIGNAL (P/N) T41 18YL/DB 2 TRS T41 SIGNAL (P/N) T41 20YL/DB 2 STARTER SOLENOID CONTROL T752 20DG/OR 3-4 FUEL PUMP CONTROL K31 20BR 5 WIPER PARK SWITCH SENSE W7 20BR/GY 6-7-8 WASHER FLUID SWITCH RETURN G932 20VT/TN 9 WASHER FLUID SWITCH SENSE W1 20BR/TN 10 TRANSMISSION CONTROL T515 20YL/DB 11 HOOD AJAR SWITCH SENSE G70 20VT/LB 12 - 13 - 14 - Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12390 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12391 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C10 Color : LT. GRAY # of pins : 22 Pin Description Circuit 1 ASD CONTROL OUTPUT K342 16BR/WT 2 FUSED B(+) A405 18RD/DB 3 FUSED B(+) A941 18RD 4-5 FUSED B(+) A104 20YL/RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12392 6 FUSED B(+) A310 16RD/LB 7 REAR WINDOW DEFOGGER CONTROL OUTPUT C15 14DB/WT 8 FUSED IGNITION SWITCH OUTPUT (RUN-START) F12 14PK/RD 9 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 10 - 11 HORN CONTROL OUTPUT X22 18GY/LB 12 WIPER LOW SPEED CONTROL OUTPUT W3 18BR/WT 13 GROUND Z971 18BK 14 HEATED MIRROR CONTROL OUTPUT C16 18DB/GY 15 FUSED B(+) A212 20RD/OR 16 - - 17 FUSED B(+) A121 14RD/YL 18 FUEL PUMP CONTROL OUTPUT A109 16OR/RD 19 HORN CONTROL OUTPUT X21 18GY/YL 20 GROUND Z953 20BK 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 FUSED B(+) A400 14TN/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12393 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C2 Color : BLACK # of pins : 13 Pin Description Circuit 1-2 WASHER PUMP MOTOR CONTROL W10 20BR 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 ADJUSTABLE PEDALS OUTPUT A72 20RD/OR 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12394 6-7-8-9 FRONT AXLE LOCK CONTROL G304 20VT/DB 10 A/C CLUTCH CONTROL C13 20LB 10 A/C CLUTCH CONTROL C13 20LB/OR 11 ASD CONTROL K51 20BR/WT 12 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/OR 13 GROUND Z117 20BK/WT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12395 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C3 Color : BLACK # of pins : 22 Pin Description Circuit 1 FUSED B(+) A209 10RD 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F984 18PK/YL 4-5 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F983 20PK/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12396 6 FUSED B(+) A205 18RD/OR 7-8 FUSED B(+) A944 20RD 9 FUSED B(+) A116 16YL/RD 10 FUSED B(+) A118 18RD/OR 11 - 12 FUSED B(+) A918 20RD 12 FUSED B(+) A918 16RD 13 FUSED IGNITION SWITCH OUTPUT (RUN) F921 20PK/LB 14 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 15 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 16 FUSED B(+) A930 16RD 17 FUSED IGNITION SWITCH OUTPUT (RUN-START) F942 10PK/LG 18 TRAILER TOW LEFT TURN RELAY OUTPUTL673 18YL 19 TRAILER TOW RIGHT TURN RELAY OUTPUT L674 18LG 20 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 21 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 22 FUSED IGNITION SWITCH OUTPUT (RUN-START) F12 14PK/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12397 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C4 Color : LT. GRAY # of pins : 13 Pin Description Circuit 1 GROUND Z118 16BK/YL 2 SHIFT MOTOR CONTROL A T102 16YL 3 SHIFT MOTOR CONTROL B T101 16DG 4-5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12398 6-7-8 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 9 5 VOLT SUPPLY T103 20YL/OR 10 MODE SENSOR A D201 20WT/DG 11 SENSOR RETURN G180 20VT/YL 12 FUSED B(+) A880 20DB/RD 13 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12399 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C5 Color : BLACK # of pins : 10 Pin Description Circuit 1 LEFT FRONT TURN LAMP DRIVER L61 20WT/LG 2 RIGHT FRONT TURN LAMP DRIVER L60 20WT/TN 3 RIGHT HIGH BEAM DRIVER L34 20WT/GY 4 LEFT LOW BEAM DRIVER L43 20WT/DB 5 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12400 6-7-8 AAT SIGNAL G31 20VT/LG 9 AAT RETURN G930 20VT/TN 10 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12401 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C6 Color : BROWN # of pins : 16 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/LG 2 DIAGNOSTIC CAN C (+) D52 20WT/LB 3 CAN B BUS (+) D55 20WT/OR 4 LEFT REAR TURN LAMP DRIVER L63 20WT/DG 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12402 6 RIGHT REAR TURN LAMP DRIVER L62 20WT/YL 7 BRAKE LAMP SWITCH OUTPUT L50 20WT/TN 8-9 CAN C BUS (-) D64 20WT/LB 10 DIAGNOSTIC CAN C (-) D51 20WT/BR 11 CAN B BUS (-) D54 20WT 12 - 13 - 14 - 15 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 16 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12403 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C7 Color : BLUE # of pins : 14 Pin Description Circuit 1-2-3 RIGHT LOW BEAM DRIVER L44 20WT/TN 4 LEFT HIGH BEAM DRIVER L33 20WT/LG 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12404 6-7 A/C PRESSURE 5 VOLT SUPPLY C818 20LB/OR 8 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY 9-10 - 11 - 12 A/C PRESSURE SIGNAL C18 20LB/BR 13 A/C PRESSURE GROUND C918 20BK/LB 14 IGNITION START T751 20YL Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12405 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C8 Color : LT. GRAY # of pins : 12 Pin Description Circuit 1-2 FUSED B(+) A919 20RD 3 FUSED B(+) A106 20LB/RD 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 5 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20PK/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12406 6 FUSED B(+) A100 14RD/VT 7 FUSED B(+) A210 12OR/RD 8 FUSED B(+) A940 18RD 9 FUSED B(+) A103 18GY/RD 10 FOG LAMP CONTROL OUTPUT L89 18WT/YL 11 BACKUP LAMP FEED L1 18WT/LG 12 FUEL HEATER CONTROL OUTPUT A961 14RD 12 CONDENSER FAN CONTROL OUTPUT C123 12LB/WT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12407 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C9 Color : BLACK # of pins : 12 Pin Description Circuit 1 FUSED B(+) A111 16DG/RD 2 STARTER MOTOR CONTROL OUTPUT T750 14YL/GY 3 A/C CLUTCH CONTROL OUTPUT C3 20DB/YL 4 WIPER MOTOR HIGH SPEED FEED W4 16BR/OR 5 FUSED B(+) A114 18GY/RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12408 6 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 10PK/YL 7-8 FUSED PARK LAMP FEED L7 20WT/YL 9 FUSED PARK LAMP FEED L678 18BR 10 FUSED PARK LAMP FEED L70 20WT/GY 11 - 12 FUSED B(+) A107 12TN/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12409 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (DIESEL) Pin Description Circuit 1 B(+) A0 6RD Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12410 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12411 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (GAS) Pin Description Circuit 1 B(+) A11 8LB Pin Description Circuit 1 B(+) A0 6RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12412 Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12413 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12414 Power Distribution Module: Diagrams Auxiliary PDC Box Component ID: 22 Component : AUXILIARY PDC BOX Connector: Name : AUXILIARY PDC BOX Color : # of pins : 10 Qualifier : (UPFITTER PACKAGE) Pin Description Circuit 1 FUSED B(+) A420 10RD 2 3 FUSED B(+) A420 10RD 4 FUSED B(+) A422 14RD 5 FUSED B(+) A420 10RD 6 FUSED B(+) A423 14PK 7 8 FUSED IGNITION SWITCH OUTPUT (RUN) F922 16PK/RD 9 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 10 GROUND Z912 20BK Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12415 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Description Power Distribution Module: Description and Operation Description DESCRIPTION The Totally Integrated Power Module (2)(TIPM) is a combination unit that performs the functions of the Power Distribution Center (PDC) and the Front Control Module. The TIPM is a printed circuit board based module that contains fuses, internal relays and a microprocessor that performs the functions previously executed by the FCM. The TIPM (2) is located in the engine compartment, next to the battery (1) and connects directly to the B+ cable (5) via a stud located on top of the unit. The ground connection is via electrical connectors. The TIPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic TIPM housing includes a base and cover. The TIPM cover is easily opened or removed for service and has a fuse and relay layout map integral to the inside surface of the cover. The TIPM housing base and cover are secured in place via mounting tabs. The mounting tabs secure the TIPM (2) to the battery tray mounting bracket (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Description > Page 12418 Power Distribution Module: Description and Operation Operation OPERATION All of the current from the battery and the generator output enters the Totally Integrated Power Module (TIPM) via a stud on the top of the module. The TIPM cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal Power Distribution Module: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the B+ terminal nut (6) from the Totally Integrated Power Module (2)(TIPM) B+ terminal. Remove the B+ cable (5) from the TIPM (2). 3. Using a suitable flat blade tool, disengage the TIPM (2) upper retaining tabs from the battery tray bracket (3). 4. Grasp the TIPM (1) and rotate the assembly up to free it from its mounting bracket (3). Position the assembly upside down to access the electrical connectors located on the bottom of the unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal > Page 12421 5. Disconnect the electrical connectors (2) by depressing the locking tab and rotating the connector arm outboard, until the connector is free from the TIPM assembly (1). Be certain to pull the connectors straight off. 6. Remove the TIPM (1) from the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal > Page 12422 Power Distribution Module: Service and Repair Installation INSTALLATION 1. Position the Totally Integrated Power Module (1)(TIPM) into the vehicle. NOTE: Totally Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors (2) by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the TIPM assembly (1). 3. Turn the TIPM (1) so that the connector side is facing down. Install the assembly onto the TIPM battery tray bracket (3) making sure to line up the lower retaining tab with the retaining slot in the tray (1). 4. Push the TIPM (1) downward to lock the upper retaining clips into the bracket (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal > Page 12423 5. Install the B+ terminal cable (5) and nut (6) on the B+ terminal of the TIPM (2). 6. Connect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Power Distribution Module: Customer Interest Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 12433 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 12434 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 12435 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 12436 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: Customer Interest Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12441 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12442 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12443 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12444 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Power Distribution Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 12450 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 12451 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 12452 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 12453 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: All Technical Service Bulletins Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12458 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12459 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12460 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12461 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead Power Distribution Module: Locations Module-Electronic Overhead Component ID: 202 Component : MODULE-ELECTRONIC OVERHEAD Connector: Name : MODULE-ELECTRONIC OVERHEAD Color : BLACK # of pins : 6 Qualifier : (EXCEPT BASE) Pin Description Circuit 1-2 FUSED B(+) A114 18GY/RD 3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT 5 GROUND Z13 20BK/WT 6-- Component Location - 53 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12464 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12465 Power Distribution Module: Locations Module-Totally Integrated Power Component ID: 213 Component : MODULE-TOTALLY INTEGRATED POWER Connector: Name : MODULE-TOTALLY INTEGRATED POWER C1 Color : LT. GRAY # of pins : 14 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 2 TRS T41 SIGNAL (P/N) T41 18YL/DB 2 TRS T41 SIGNAL (P/N) T41 20YL/DB 2 STARTER SOLENOID CONTROL T752 20DG/OR 3-4 FUEL PUMP CONTROL K31 20BR 5 WIPER PARK SWITCH SENSE W7 20BR/GY 6-7-8 WASHER FLUID SWITCH RETURN G932 20VT/TN 9 WASHER FLUID SWITCH SENSE W1 20BR/TN 10 TRANSMISSION CONTROL T515 20YL/DB 11 HOOD AJAR SWITCH SENSE G70 20VT/LB 12 - 13 - 14 - Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12466 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12467 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C10 Color : LT. GRAY # of pins : 22 Pin Description Circuit 1 ASD CONTROL OUTPUT K342 16BR/WT 2 FUSED B(+) A405 18RD/DB 3 FUSED B(+) A941 18RD 4-5 FUSED B(+) A104 20YL/RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12468 6 FUSED B(+) A310 16RD/LB 7 REAR WINDOW DEFOGGER CONTROL OUTPUT C15 14DB/WT 8 FUSED IGNITION SWITCH OUTPUT (RUN-START) F12 14PK/RD 9 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 10 - 11 HORN CONTROL OUTPUT X22 18GY/LB 12 WIPER LOW SPEED CONTROL OUTPUT W3 18BR/WT 13 GROUND Z971 18BK 14 HEATED MIRROR CONTROL OUTPUT C16 18DB/GY 15 FUSED B(+) A212 20RD/OR 16 - - 17 FUSED B(+) A121 14RD/YL 18 FUEL PUMP CONTROL OUTPUT A109 16OR/RD 19 HORN CONTROL OUTPUT X21 18GY/YL 20 GROUND Z953 20BK 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 FUSED B(+) A400 14TN/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12469 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C2 Color : BLACK # of pins : 13 Pin Description Circuit 1-2 WASHER PUMP MOTOR CONTROL W10 20BR 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 ADJUSTABLE PEDALS OUTPUT A72 20RD/OR 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12470 6-7-8-9 FRONT AXLE LOCK CONTROL G304 20VT/DB 10 A/C CLUTCH CONTROL C13 20LB 10 A/C CLUTCH CONTROL C13 20LB/OR 11 ASD CONTROL K51 20BR/WT 12 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/OR 13 GROUND Z117 20BK/WT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12471 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C3 Color : BLACK # of pins : 22 Pin Description Circuit 1 FUSED B(+) A209 10RD 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F984 18PK/YL 4-5 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F983 20PK/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12472 6 FUSED B(+) A205 18RD/OR 7-8 FUSED B(+) A944 20RD 9 FUSED B(+) A116 16YL/RD 10 FUSED B(+) A118 18RD/OR 11 - 12 FUSED B(+) A918 20RD 12 FUSED B(+) A918 16RD 13 FUSED IGNITION SWITCH OUTPUT (RUN) F921 20PK/LB 14 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 15 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 16 FUSED B(+) A930 16RD 17 FUSED IGNITION SWITCH OUTPUT (RUN-START) F942 10PK/LG 18 TRAILER TOW LEFT TURN RELAY OUTPUTL673 18YL 19 TRAILER TOW RIGHT TURN RELAY OUTPUT L674 18LG 20 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 21 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 22 FUSED IGNITION SWITCH OUTPUT (RUN-START) F12 14PK/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12473 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C4 Color : LT. GRAY # of pins : 13 Pin Description Circuit 1 GROUND Z118 16BK/YL 2 SHIFT MOTOR CONTROL A T102 16YL 3 SHIFT MOTOR CONTROL B T101 16DG 4-5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12474 6-7-8 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 9 5 VOLT SUPPLY T103 20YL/OR 10 MODE SENSOR A D201 20WT/DG 11 SENSOR RETURN G180 20VT/YL 12 FUSED B(+) A880 20DB/RD 13 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12475 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C5 Color : BLACK # of pins : 10 Pin Description Circuit 1 LEFT FRONT TURN LAMP DRIVER L61 20WT/LG 2 RIGHT FRONT TURN LAMP DRIVER L60 20WT/TN 3 RIGHT HIGH BEAM DRIVER L34 20WT/GY 4 LEFT LOW BEAM DRIVER L43 20WT/DB 5 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12476 6-7-8 AAT SIGNAL G31 20VT/LG 9 AAT RETURN G930 20VT/TN 10 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12477 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C6 Color : BROWN # of pins : 16 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/LG 2 DIAGNOSTIC CAN C (+) D52 20WT/LB 3 CAN B BUS (+) D55 20WT/OR 4 LEFT REAR TURN LAMP DRIVER L63 20WT/DG 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12478 6 RIGHT REAR TURN LAMP DRIVER L62 20WT/YL 7 BRAKE LAMP SWITCH OUTPUT L50 20WT/TN 8-9 CAN C BUS (-) D64 20WT/LB 10 DIAGNOSTIC CAN C (-) D51 20WT/BR 11 CAN B BUS (-) D54 20WT 12 - 13 - 14 - 15 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 16 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12479 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C7 Color : BLUE # of pins : 14 Pin Description Circuit 1-2-3 RIGHT LOW BEAM DRIVER L44 20WT/TN 4 LEFT HIGH BEAM DRIVER L33 20WT/LG 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12480 6-7 A/C PRESSURE 5 VOLT SUPPLY C818 20LB/OR 8 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY 9-10 - 11 - 12 A/C PRESSURE SIGNAL C18 20LB/BR 13 A/C PRESSURE GROUND C918 20BK/LB 14 IGNITION START T751 20YL Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12481 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C8 Color : LT. GRAY # of pins : 12 Pin Description Circuit 1-2 FUSED B(+) A919 20RD 3 FUSED B(+) A106 20LB/RD 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 5 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20PK/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12482 6 FUSED B(+) A100 14RD/VT 7 FUSED B(+) A210 12OR/RD 8 FUSED B(+) A940 18RD 9 FUSED B(+) A103 18GY/RD 10 FOG LAMP CONTROL OUTPUT L89 18WT/YL 11 BACKUP LAMP FEED L1 18WT/LG 12 FUEL HEATER CONTROL OUTPUT A961 14RD 12 CONDENSER FAN CONTROL OUTPUT C123 12LB/WT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12483 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C9 Color : BLACK # of pins : 12 Pin Description Circuit 1 FUSED B(+) A111 16DG/RD 2 STARTER MOTOR CONTROL OUTPUT T750 14YL/GY 3 A/C CLUTCH CONTROL OUTPUT C3 20DB/YL 4 WIPER MOTOR HIGH SPEED FEED W4 16BR/OR 5 FUSED B(+) A114 18GY/RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12484 6 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 10PK/YL 7-8 FUSED PARK LAMP FEED L7 20WT/YL 9 FUSED PARK LAMP FEED L678 18BR 10 FUSED PARK LAMP FEED L70 20WT/GY 11 - 12 FUSED B(+) A107 12TN/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12485 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (DIESEL) Pin Description Circuit 1 B(+) A0 6RD Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12486 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12487 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (GAS) Pin Description Circuit 1 B(+) A11 8LB Pin Description Circuit 1 B(+) A0 6RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12488 Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12489 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12490 Power Distribution Module: Locations Auxiliary PDC Box Component ID: 22 Component : AUXILIARY PDC BOX Connector: Name : AUXILIARY PDC BOX Color : # of pins : 10 Qualifier : (UPFITTER PACKAGE) Pin Description Circuit 1 FUSED B(+) A420 10RD 2 3 FUSED B(+) A420 10RD 4 FUSED B(+) A422 14RD 5 FUSED B(+) A420 10RD 6 FUSED B(+) A423 14PK 7 8 FUSED IGNITION SWITCH OUTPUT (RUN) F922 16PK/RD 9 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 10 GROUND Z912 20BK Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Electronic Overhead > Page 12491 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead Power Distribution Module: Diagrams Module-Electronic Overhead Component ID: 202 Component : MODULE-ELECTRONIC OVERHEAD Connector: Name : MODULE-ELECTRONIC OVERHEAD Color : BLACK # of pins : 6 Qualifier : (EXCEPT BASE) Pin Description Circuit 1-2 FUSED B(+) A114 18GY/RD 3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT 5 GROUND Z13 20BK/WT 6-- Component Location - 53 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12494 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12495 Power Distribution Module: Diagrams Module-Totally Integrated Power Component ID: 213 Component : MODULE-TOTALLY INTEGRATED POWER Connector: Name : MODULE-TOTALLY INTEGRATED POWER C1 Color : LT. GRAY # of pins : 14 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) F1 20PK/WT 2 TRS T41 SIGNAL (P/N) T41 18YL/DB 2 TRS T41 SIGNAL (P/N) T41 20YL/DB 2 STARTER SOLENOID CONTROL T752 20DG/OR 3-4 FUEL PUMP CONTROL K31 20BR 5 WIPER PARK SWITCH SENSE W7 20BR/GY 6-7-8 WASHER FLUID SWITCH RETURN G932 20VT/TN 9 WASHER FLUID SWITCH SENSE W1 20BR/TN 10 TRANSMISSION CONTROL T515 20YL/DB 11 HOOD AJAR SWITCH SENSE G70 20VT/LB 12 - 13 - 14 - Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12496 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12497 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C10 Color : LT. GRAY # of pins : 22 Pin Description Circuit 1 ASD CONTROL OUTPUT K342 16BR/WT 2 FUSED B(+) A405 18RD/DB 3 FUSED B(+) A941 18RD 4-5 FUSED B(+) A104 20YL/RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12498 6 FUSED B(+) A310 16RD/LB 7 REAR WINDOW DEFOGGER CONTROL OUTPUT C15 14DB/WT 8 FUSED IGNITION SWITCH OUTPUT (RUN-START) F12 14PK/RD 9 TRANSMISSION CONTROL OUTPUT T16 16YL/OR 10 - 11 HORN CONTROL OUTPUT X22 18GY/LB 12 WIPER LOW SPEED CONTROL OUTPUT W3 18BR/WT 13 GROUND Z971 18BK 14 HEATED MIRROR CONTROL OUTPUT C16 18DB/GY 15 FUSED B(+) A212 20RD/OR 16 - - 17 FUSED B(+) A121 14RD/YL 18 FUEL PUMP CONTROL OUTPUT A109 16OR/RD 19 HORN CONTROL OUTPUT X21 18GY/YL 20 GROUND Z953 20BK 21 TRS T41 SIGNAL (P/N) T41 20YL/DB 22 FUSED B(+) A400 14TN/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12499 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C2 Color : BLACK # of pins : 13 Pin Description Circuit 1-2 WASHER PUMP MOTOR CONTROL W10 20BR 3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 ADJUSTABLE PEDALS OUTPUT A72 20RD/OR 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12500 6-7-8-9 FRONT AXLE LOCK CONTROL G304 20VT/DB 10 A/C CLUTCH CONTROL C13 20LB 10 A/C CLUTCH CONTROL C13 20LB/OR 11 ASD CONTROL K51 20BR/WT 12 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/OR 13 GROUND Z117 20BK/WT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12501 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C3 Color : BLACK # of pins : 22 Pin Description Circuit 1 FUSED B(+) A209 10RD 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F984 18PK/YL 4-5 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F983 20PK/YL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12502 6 FUSED B(+) A205 18RD/OR 7-8 FUSED B(+) A944 20RD 9 FUSED B(+) A116 16YL/RD 10 FUSED B(+) A118 18RD/OR 11 - 12 FUSED B(+) A918 20RD 12 FUSED B(+) A918 16RD 13 FUSED IGNITION SWITCH OUTPUT (RUN) F921 20PK/LB 14 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 15 FUSED IGNITION SWITCH OUTPUT (RUN-START) F202 20PK/GY 16 FUSED B(+) A930 16RD 17 FUSED IGNITION SWITCH OUTPUT (RUN-START) F942 10PK/LG 18 TRAILER TOW LEFT TURN RELAY OUTPUTL673 18YL 19 TRAILER TOW RIGHT TURN RELAY OUTPUT L674 18LG 20 FUSED IGNITION SWITCH OUTPUT (RUN-START) F960 20PK/LG 21 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 22 FUSED IGNITION SWITCH OUTPUT (RUN-START) F12 14PK/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12503 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C4 Color : LT. GRAY # of pins : 13 Pin Description Circuit 1 GROUND Z118 16BK/YL 2 SHIFT MOTOR CONTROL A T102 16YL 3 SHIFT MOTOR CONTROL B T101 16DG 4-5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12504 6-7-8 T-CASE MOTOR BRAKE SIGNAL T300 20YL/GY 9 5 VOLT SUPPLY T103 20YL/OR 10 MODE SENSOR A D201 20WT/DG 11 SENSOR RETURN G180 20VT/YL 12 FUSED B(+) A880 20DB/RD 13 FRONT AXLE LOCK SIGNAL G303 20VT/DG Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12505 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C5 Color : BLACK # of pins : 10 Pin Description Circuit 1 LEFT FRONT TURN LAMP DRIVER L61 20WT/LG 2 RIGHT FRONT TURN LAMP DRIVER L60 20WT/TN 3 RIGHT HIGH BEAM DRIVER L34 20WT/GY 4 LEFT LOW BEAM DRIVER L43 20WT/DB 5 INPUT SPEED SENSOR 2 (N3) SIGNAL T340 20DG/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12506 6-7-8 AAT SIGNAL G31 20VT/LG 9 AAT RETURN G930 20VT/TN 10 INPUT SPEED SENSOR 2 (N3) RETURN T71 20YL/OR Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12507 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C6 Color : BROWN # of pins : 16 Pin Description Circuit 1 CAN C BUS (+) D65 20WT/LG 2 DIAGNOSTIC CAN C (+) D52 20WT/LB 3 CAN B BUS (+) D55 20WT/OR 4 LEFT REAR TURN LAMP DRIVER L63 20WT/DG 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12508 6 RIGHT REAR TURN LAMP DRIVER L62 20WT/YL 7 BRAKE LAMP SWITCH OUTPUT L50 20WT/TN 8-9 CAN C BUS (-) D64 20WT/LB 10 DIAGNOSTIC CAN C (-) D51 20WT/BR 11 CAN B BUS (-) D54 20WT 12 - 13 - 14 - 15 INPUT SPEED SENSOR 1 (N2) SIGNAL T70 20YL 16 INPUT SPEED SENSOR 1 (N2) RETURN T341 20DG/VT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12509 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C7 Color : BLUE # of pins : 14 Pin Description Circuit 1-2-3 RIGHT LOW BEAM DRIVER L44 20WT/TN 4 LEFT HIGH BEAM DRIVER L33 20WT/LG 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12510 6-7 A/C PRESSURE 5 VOLT SUPPLY C818 20LB/OR 8 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY 9-10 - 11 - 12 A/C PRESSURE SIGNAL C18 20LB/BR 13 A/C PRESSURE GROUND C918 20BK/LB 14 IGNITION START T751 20YL Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12511 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C8 Color : LT. GRAY # of pins : 12 Pin Description Circuit 1-2 FUSED B(+) A919 20RD 3 FUSED B(+) A106 20LB/RD 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 5 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20PK/VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12512 6 FUSED B(+) A100 14RD/VT 7 FUSED B(+) A210 12OR/RD 8 FUSED B(+) A940 18RD 9 FUSED B(+) A103 18GY/RD 10 FOG LAMP CONTROL OUTPUT L89 18WT/YL 11 BACKUP LAMP FEED L1 18WT/LG 12 FUEL HEATER CONTROL OUTPUT A961 14RD 12 CONDENSER FAN CONTROL OUTPUT C123 12LB/WT Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12513 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C9 Color : BLACK # of pins : 12 Pin Description Circuit 1 FUSED B(+) A111 16DG/RD 2 STARTER MOTOR CONTROL OUTPUT T750 14YL/GY 3 A/C CLUTCH CONTROL OUTPUT C3 20DB/YL 4 WIPER MOTOR HIGH SPEED FEED W4 16BR/OR 5 FUSED B(+) A114 18GY/RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12514 6 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 10PK/YL 7-8 FUSED PARK LAMP FEED L7 20WT/YL 9 FUSED PARK LAMP FEED L678 18BR 10 FUSED PARK LAMP FEED L70 20WT/GY 11 - 12 FUSED B(+) A107 12TN/RD Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12515 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (DIESEL) Pin Description Circuit 1 B(+) A0 6RD Component Location - 33 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12516 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12517 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (GAS) Pin Description Circuit 1 B(+) A11 8LB Pin Description Circuit 1 B(+) A0 6RD Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12518 Component Location - 33 Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12519 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12520 Power Distribution Module: Diagrams Auxiliary PDC Box Component ID: 22 Component : AUXILIARY PDC BOX Connector: Name : AUXILIARY PDC BOX Color : # of pins : 10 Qualifier : (UPFITTER PACKAGE) Pin Description Circuit 1 FUSED B(+) A420 10RD 2 3 FUSED B(+) A420 10RD 4 FUSED B(+) A422 14RD 5 FUSED B(+) A420 10RD 6 FUSED B(+) A423 14PK 7 8 FUSED IGNITION SWITCH OUTPUT (RUN) F922 16PK/RD 9 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 10 GROUND Z912 20BK Component Location - 34 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Electronic Overhead > Page 12521 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Description Power Distribution Module: Description and Operation Description DESCRIPTION The Totally Integrated Power Module (2)(TIPM) is a combination unit that performs the functions of the Power Distribution Center (PDC) and the Front Control Module. The TIPM is a printed circuit board based module that contains fuses, internal relays and a microprocessor that performs the functions previously executed by the FCM. The TIPM (2) is located in the engine compartment, next to the battery (1) and connects directly to the B+ cable (5) via a stud located on top of the unit. The ground connection is via electrical connectors. The TIPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic TIPM housing includes a base and cover. The TIPM cover is easily opened or removed for service and has a fuse and relay layout map integral to the inside surface of the cover. The TIPM housing base and cover are secured in place via mounting tabs. The mounting tabs secure the TIPM (2) to the battery tray mounting bracket (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Description > Page 12524 Power Distribution Module: Description and Operation Operation OPERATION All of the current from the battery and the generator output enters the Totally Integrated Power Module (TIPM) via a stud on the top of the module. The TIPM cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal Power Distribution Module: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the B+ terminal nut (6) from the Totally Integrated Power Module (2)(TIPM) B+ terminal. Remove the B+ cable (5) from the TIPM (2). 3. Using a suitable flat blade tool, disengage the TIPM (2) upper retaining tabs from the battery tray bracket (3). 4. Grasp the TIPM (1) and rotate the assembly up to free it from its mounting bracket (3). Position the assembly upside down to access the electrical connectors located on the bottom of the unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal > Page 12527 5. Disconnect the electrical connectors (2) by depressing the locking tab and rotating the connector arm outboard, until the connector is free from the TIPM assembly (1). Be certain to pull the connectors straight off. 6. Remove the TIPM (1) from the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal > Page 12528 Power Distribution Module: Service and Repair Installation INSTALLATION 1. Position the Totally Integrated Power Module (1)(TIPM) into the vehicle. NOTE: Totally Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors (2) by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the TIPM assembly (1). 3. Turn the TIPM (1) so that the connector side is facing down. Install the assembly onto the TIPM battery tray bracket (3) making sure to line up the lower retaining tab with the retaining slot in the tray (1). 4. Push the TIPM (1) downward to lock the upper retaining clips into the bracket (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal > Page 12529 5. Install the B+ terminal cable (5) and nut (6) on the B+ terminal of the TIPM (2). 6. Connect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) Relay Box: Locations Fuses (Integrated Power Module) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) > Page 12534 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) > Page 12535 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) > Page 12536 Relay Box: Locations Auxiliary PDC Box (Upfitter Package) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) Relay Box: Application and ID Fuses (Integrated Power Module) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 12539 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 12540 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 12541 Relay Box: Application and ID Auxiliary PDC Box (Upfitter Package) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) Relay Box: Locations Fuses (Integrated Power Module) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) > Page 12546 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) > Page 12547 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) > Page 12548 Relay Box: Locations Auxiliary PDC Box (Upfitter Package) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) Relay Box: Application and ID Fuses (Integrated Power Module) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 12551 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 12552 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) > Page 12553 Relay Box: Application and ID Auxiliary PDC Box (Upfitter Package) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads Alignment: Customer Interest Steering - Front End Shimmy On Rough Roads NUMBER: 22-005-06 GROUP: Tire & Wheels DATE: October 07, 2006 SUBJECT: Front End Shimmy On 4x4 Vehicles When Traveling Over Rough Surfaces In The Road OVERVIEW: This bulletin involves verifying the condition of the vehicle front suspension and steering components, and adjusting the front tire pressure. MODELS: 2003 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to four wheel drive (4x4) 2500 and 3500 model vehicles. SYMPTOM/CONDITION: The customer may experience a self sustaining vibration (shimmy) felt in the front end of the vehicle after striking a bump or pothole. DIAGNOSIS: If the customer experiences the above condition perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on an alignment rack (drive-on lift). 2. Verify the road tires are correctly sized and the tire tread is not excessively worn. Replace any worn tire before proceeding. Any new or old replacement tire should be equal to the original tires that came with the vehicle when it was new. Tire wear is not covered by the vehicle warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads > Page 12563 3. Set the tire pressure for the FRONT TIRES to the following specification, regardless of the load being carried by the vehicle. 4. Set the tire pressure for the REAR TIRES as recommended for the vehicle configuration and load that is being carried at the time. 5. Verify that the steering damper is operating correctly. a. Unbolt the end of the damper at the axle end. b. Cycle the damper rod by hand. c. There should be resistance to motion in both directions of the damper rod. d. Replace the damper if no resistance is present. 6. Verify both outer tie rod ends dust covers are not worn. a. Attempt to rotate the dust cover by hand. b. If the dust cover on an outer tie rod end can be rotated, or is free and loose, then replace the tie rod (regardless of joint wear). 7. Inspect each outer tie rod end for internal wear. a. Maximum allowed wear (joint travel) for a tie rod end is 1.15 mm (0.045 in.). b. Install a dial indicator to the tie rod end (in-line with the vertical stud of the tie rod end). c. With a pry bar placed between the steering linkage and the axle tube, pry upwards while measuring the amount of joint travel (wear). d. Measure the amount of wear in the other outer tie rod end joint. e. If wear (joint travel) in either outer tie rod end is greater than 1.15 mm (0.045 in.), then replace the worn tie rod end. 8. Verify the torque on each outer tie rod end stud nut. The nut should be tightened to 122 Nm (90 ft. lbs.). 9. Make sure any worn outer tie rod ends have been replaced before proceeding further. 10. Verify all other steering linkage connections are tightened to their torque specifications. 11. Grease both outer tie rod ends (even if the outer tie rod is new). Apply sufficient grease to each tie rod end until grease is seen purging from the joint at the dust seal. 12. Align the vehicle front end. Adjust to specifications. 13. Road test the vehicle and verify the shimmy condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads > Page 12564 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads Alignment: All Technical Service Bulletins Steering - Front End Shimmy On Rough Roads NUMBER: 22-005-06 GROUP: Tire & Wheels DATE: October 07, 2006 SUBJECT: Front End Shimmy On 4x4 Vehicles When Traveling Over Rough Surfaces In The Road OVERVIEW: This bulletin involves verifying the condition of the vehicle front suspension and steering components, and adjusting the front tire pressure. MODELS: 2003 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to four wheel drive (4x4) 2500 and 3500 model vehicles. SYMPTOM/CONDITION: The customer may experience a self sustaining vibration (shimmy) felt in the front end of the vehicle after striking a bump or pothole. DIAGNOSIS: If the customer experiences the above condition perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on an alignment rack (drive-on lift). 2. Verify the road tires are correctly sized and the tire tread is not excessively worn. Replace any worn tire before proceeding. Any new or old replacement tire should be equal to the original tires that came with the vehicle when it was new. Tire wear is not covered by the vehicle warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads > Page 12570 3. Set the tire pressure for the FRONT TIRES to the following specification, regardless of the load being carried by the vehicle. 4. Set the tire pressure for the REAR TIRES as recommended for the vehicle configuration and load that is being carried at the time. 5. Verify that the steering damper is operating correctly. a. Unbolt the end of the damper at the axle end. b. Cycle the damper rod by hand. c. There should be resistance to motion in both directions of the damper rod. d. Replace the damper if no resistance is present. 6. Verify both outer tie rod ends dust covers are not worn. a. Attempt to rotate the dust cover by hand. b. If the dust cover on an outer tie rod end can be rotated, or is free and loose, then replace the tie rod (regardless of joint wear). 7. Inspect each outer tie rod end for internal wear. a. Maximum allowed wear (joint travel) for a tie rod end is 1.15 mm (0.045 in.). b. Install a dial indicator to the tie rod end (in-line with the vertical stud of the tie rod end). c. With a pry bar placed between the steering linkage and the axle tube, pry upwards while measuring the amount of joint travel (wear). d. Measure the amount of wear in the other outer tie rod end joint. e. If wear (joint travel) in either outer tie rod end is greater than 1.15 mm (0.045 in.), then replace the worn tie rod end. 8. Verify the torque on each outer tie rod end stud nut. The nut should be tightened to 122 Nm (90 ft. lbs.). 9. Make sure any worn outer tie rod ends have been replaced before proceeding further. 10. Verify all other steering linkage connections are tightened to their torque specifications. 11. Grease both outer tie rod ends (even if the outer tie rod is new). Apply sufficient grease to each tie rod end until grease is seen purging from the joint at the dust seal. 12. Align the vehicle front end. Adjust to specifications. 13. Road test the vehicle and verify the shimmy condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads > Page 12571 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 12572 Alignment: By Symptom Technical Service Bulletin # 22-005-06 Date: 061007 Steering - Front End Shimmy On Rough Roads NUMBER: 22-005-06 GROUP: Tire & Wheels DATE: October 07, 2006 SUBJECT: Front End Shimmy On 4x4 Vehicles When Traveling Over Rough Surfaces In The Road OVERVIEW: This bulletin involves verifying the condition of the vehicle front suspension and steering components, and adjusting the front tire pressure. MODELS: 2003 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to four wheel drive (4x4) 2500 and 3500 model vehicles. SYMPTOM/CONDITION: The customer may experience a self sustaining vibration (shimmy) felt in the front end of the vehicle after striking a bump or pothole. DIAGNOSIS: If the customer experiences the above condition perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on an alignment rack (drive-on lift). 2. Verify the road tires are correctly sized and the tire tread is not excessively worn. Replace any worn tire before proceeding. Any new or old replacement tire should be equal to the original tires that came with the vehicle when it was new. Tire wear is not covered by the vehicle warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 12573 3. Set the tire pressure for the FRONT TIRES to the following specification, regardless of the load being carried by the vehicle. 4. Set the tire pressure for the REAR TIRES as recommended for the vehicle configuration and load that is being carried at the time. 5. Verify that the steering damper is operating correctly. a. Unbolt the end of the damper at the axle end. b. Cycle the damper rod by hand. c. There should be resistance to motion in both directions of the damper rod. d. Replace the damper if no resistance is present. 6. Verify both outer tie rod ends dust covers are not worn. a. Attempt to rotate the dust cover by hand. b. If the dust cover on an outer tie rod end can be rotated, or is free and loose, then replace the tie rod (regardless of joint wear). 7. Inspect each outer tie rod end for internal wear. a. Maximum allowed wear (joint travel) for a tie rod end is 1.15 mm (0.045 in.). b. Install a dial indicator to the tie rod end (in-line with the vertical stud of the tie rod end). c. With a pry bar placed between the steering linkage and the axle tube, pry upwards while measuring the amount of joint travel (wear). d. Measure the amount of wear in the other outer tie rod end joint. e. If wear (joint travel) in either outer tie rod end is greater than 1.15 mm (0.045 in.), then replace the worn tie rod end. 8. Verify the torque on each outer tie rod end stud nut. The nut should be tightened to 122 Nm (90 ft. lbs.). 9. Make sure any worn outer tie rod ends have been replaced before proceeding further. 10. Verify all other steering linkage connections are tightened to their torque specifications. 11. Grease both outer tie rod ends (even if the outer tie rod is new). Apply sufficient grease to each tie rod end until grease is seen purging from the joint at the dust seal. 12. Align the vehicle front end. Adjust to specifications. 13. Road test the vehicle and verify the shimmy condition has been corrected. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 12574 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 22-005-06 Date: 061007 Steering - Front End Shimmy On Rough Roads NUMBER: 22-005-06 GROUP: Tire & Wheels DATE: October 07, 2006 SUBJECT: Front End Shimmy On 4x4 Vehicles When Traveling Over Rough Surfaces In The Road OVERVIEW: This bulletin involves verifying the condition of the vehicle front suspension and steering components, and adjusting the front tire pressure. MODELS: 2003 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to four wheel drive (4x4) 2500 and 3500 model vehicles. SYMPTOM/CONDITION: The customer may experience a self sustaining vibration (shimmy) felt in the front end of the vehicle after striking a bump or pothole. DIAGNOSIS: If the customer experiences the above condition perform the Repair Procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 12575 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on an alignment rack (drive-on lift). 2. Verify the road tires are correctly sized and the tire tread is not excessively worn. Replace any worn tire before proceeding. Any new or old replacement tire should be equal to the original tires that came with the vehicle when it was new. Tire wear is not covered by the vehicle warranty. 3. Set the tire pressure for the FRONT TIRES to the following specification, regardless of the load being carried by the vehicle. 4. Set the tire pressure for the REAR TIRES as recommended for the vehicle configuration and load that is being carried at the time. 5. Verify that the steering damper is operating correctly. a. Unbolt the end of the damper at the axle end. b. Cycle the damper rod by hand. c. There should be resistance to motion in both directions of the damper rod. d. Replace the damper if no resistance is present. 6. Verify both outer tie rod ends dust covers are not worn. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 12576 a. Attempt to rotate the dust cover by hand. b. If the dust cover on an outer tie rod end can be rotated, or is free and loose, then replace the tie rod (regardless of joint wear). 7. Inspect each outer tie rod end for internal wear. a. Maximum allowed wear (joint travel) for a tie rod end is 1.15 mm (0.045 in.). b. Install a dial indicator to the tie rod end (in-line with the vertical stud of the tie rod end). c. With a pry bar placed between the steering linkage and the axle tube, pry upwards while measuring the amount of joint travel (wear). d. Measure the amount of wear in the other outer tie rod end joint. e. If wear (joint travel) in either outer tie rod end is greater than 1.15 mm (0.045 in.), then replace the worn tie rod end. 8. Verify the torque on each outer tie rod end stud nut. The nut should be tightened to 122 Nm (90 ft. lbs.). 9. Make sure any worn outer tie rod ends have been replaced before proceeding further. 10. Verify all other steering linkage connections are tightened to their torque specifications. 11. Grease both outer tie rod ends (even if the outer tie rod is new). Apply sufficient grease to each tie rod end until grease is seen purging from the joint at the dust seal. 12. Align the vehicle front end. Adjust to specifications. 13. Road test the vehicle and verify the shimmy condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 22-005-06 Date: 061007 Steering - Front End Shimmy On Rough Roads NUMBER: 22-005-06 GROUP: Tire & Wheels Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 12577 DATE: October 07, 2006 SUBJECT: Front End Shimmy On 4x4 Vehicles When Traveling Over Rough Surfaces In The Road OVERVIEW: This bulletin involves verifying the condition of the vehicle front suspension and steering components, and adjusting the front tire pressure. MODELS: 2003 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to four wheel drive (4x4) 2500 and 3500 model vehicles. SYMPTOM/CONDITION: The customer may experience a self sustaining vibration (shimmy) felt in the front end of the vehicle after striking a bump or pothole. DIAGNOSIS: If the customer experiences the above condition perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on an alignment rack (drive-on lift). 2. Verify the road tires are correctly sized and the tire tread is not excessively worn. Replace any worn tire before proceeding. Any new or old replacement tire should be equal to the original tires that came with the vehicle when it was new. Tire wear is not covered by the vehicle warranty. 3. Set the tire pressure for the FRONT TIRES to the following specification, regardless of the load being carried by the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 12578 4. Set the tire pressure for the REAR TIRES as recommended for the vehicle configuration and load that is being carried at the time. 5. Verify that the steering damper is operating correctly. a. Unbolt the end of the damper at the axle end. b. Cycle the damper rod by hand. c. There should be resistance to motion in both directions of the damper rod. d. Replace the damper if no resistance is present. 6. Verify both outer tie rod ends dust covers are not worn. a. Attempt to rotate the dust cover by hand. b. If the dust cover on an outer tie rod end can be rotated, or is free and loose, then replace the tie rod (regardless of joint wear). 7. Inspect each outer tie rod end for internal wear. a. Maximum allowed wear (joint travel) for a tie rod end is 1.15 mm (0.045 in.). b. Install a dial indicator to the tie rod end (in-line with the vertical stud of the tie rod end). c. With a pry bar placed between the steering linkage and the axle tube, pry upwards while measuring the amount of joint travel (wear). d. Measure the amount of wear in the other outer tie rod end joint. e. If wear (joint travel) in either outer tie rod end is greater than 1.15 mm (0.045 in.), then replace the worn tie rod end. 8. Verify the torque on each outer tie rod end stud nut. The nut should be tightened to 122 Nm (90 ft. lbs.). 9. Make sure any worn outer tie rod ends have been replaced before proceeding further. 10. Verify all other steering linkage connections are tightened to their torque specifications. 11. Grease both outer tie rod ends (even if the outer tie rod is new). Apply sufficient grease to each tie rod end until grease is seen purging from the joint at the dust seal. 12. Align the vehicle front end. Adjust to specifications. 13. Road test the vehicle and verify the shimmy condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 12579 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 22-005-06 Date: 061007 Steering - Front End Shimmy On Rough Roads NUMBER: 22-005-06 GROUP: Tire & Wheels DATE: October 07, 2006 SUBJECT: Front End Shimmy On 4x4 Vehicles When Traveling Over Rough Surfaces In The Road OVERVIEW: This bulletin involves verifying the condition of the vehicle front suspension and steering components, and adjusting the front tire pressure. MODELS: 2003 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to four wheel drive (4x4) 2500 and 3500 model vehicles. SYMPTOM/CONDITION: The customer may experience a self sustaining vibration (shimmy) felt in the front end of the vehicle after striking a bump or pothole. DIAGNOSIS: If the customer experiences the above condition perform the Repair Procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 12580 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on an alignment rack (drive-on lift). 2. Verify the road tires are correctly sized and the tire tread is not excessively worn. Replace any worn tire before proceeding. Any new or old replacement tire should be equal to the original tires that came with the vehicle when it was new. Tire wear is not covered by the vehicle warranty. 3. Set the tire pressure for the FRONT TIRES to the following specification, regardless of the load being carried by the vehicle. 4. Set the tire pressure for the REAR TIRES as recommended for the vehicle configuration and load that is being carried at the time. 5. Verify that the steering damper is operating correctly. a. Unbolt the end of the damper at the axle end. b. Cycle the damper rod by hand. c. There should be resistance to motion in both directions of the damper rod. d. Replace the damper if no resistance is present. 6. Verify both outer tie rod ends dust covers are not worn. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 12581 a. Attempt to rotate the dust cover by hand. b. If the dust cover on an outer tie rod end can be rotated, or is free and loose, then replace the tie rod (regardless of joint wear). 7. Inspect each outer tie rod end for internal wear. a. Maximum allowed wear (joint travel) for a tie rod end is 1.15 mm (0.045 in.). b. Install a dial indicator to the tie rod end (in-line with the vertical stud of the tie rod end). c. With a pry bar placed between the steering linkage and the axle tube, pry upwards while measuring the amount of joint travel (wear). d. Measure the amount of wear in the other outer tie rod end joint. e. If wear (joint travel) in either outer tie rod end is greater than 1.15 mm (0.045 in.), then replace the worn tie rod end. 8. Verify the torque on each outer tie rod end stud nut. The nut should be tightened to 122 Nm (90 ft. lbs.). 9. Make sure any worn outer tie rod ends have been replaced before proceeding further. 10. Verify all other steering linkage connections are tightened to their torque specifications. 11. Grease both outer tie rod ends (even if the outer tie rod is new). Apply sufficient grease to each tie rod end until grease is seen purging from the joint at the dust seal. 12. Align the vehicle front end. Adjust to specifications. 13. Road test the vehicle and verify the shimmy condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Ride Height Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Ride Height > Page 12584 Alignment: Specifications Wheel Alignment ALIGNMENT SPECIFICATIONS NOTE: All alignment specifications are in degrees. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Description Alignment: Description and Operation Description DESCRIPTION NOTE: Suspension components with rubber/urethane bushings should be tightened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort could be affected and premature bushing wear may occur. Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe. CAUTION: Never attempt to modify suspension or steering components by heating or bending. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Description > Page 12587 Alignment: Description and Operation Operation OPERATION - CASTER is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides less positive caster. Tilting the top of the knuckle rearward provides more positive caster. Positive caster promotes directional stability. This angle enables the front wheels to return to a straight ahead position after turns - CAMBER is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire - TOE is the difference between the leading inside edges and trailing inside edges of the front tires. Wheel toe position out of specification cause's unstable steering, uneven tire wear and steering wheel off- center. The wheel toe position is the final front wheel alignment adjustment - THRUST ANGLE is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Page 12588 Alignment: Testing and Inspection PRE-ALIGNMENT INSPECTION Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to Suspension and Steering System Diagnosis Chart below for additional information. See: Steering/Testing and Inspection/Symptom Related Diagnostic Procedures 1. Inspect tires for size, air pressure and tread wear. 2. Inspect front wheel bearings for wear. 3. Inspect front wheels for excessive radial or lateral runout and balance. 4. Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding. 5. Inspect suspension components for wear and noise. 6. Road test the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Page 12589 Suspension And Steering System Diagnosis (Part 1) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Page 12590 Suspension And Steering System Diagnosis (Part 2) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber And Caster Adjustment Alignment: Service and Repair Camber And Caster Adjustment CAMBER AND CASTER ADJUSTMENT Camber and caster angle adjustments involve changing the position of the lower control arm (2) in conjunction with the slotted holes in the frame brackets (1). Vehicle should be at normal ride height. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber And Caster Adjustment > Page 12593 Alignment: Service and Repair Toe Adjustment TOE ADJUSTMENT The wheel toe position adjustment is the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. 2. Loosen the tie rod jam nuts (1). NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. 3. Adjust the wheel toe position by turning the inner tie rod (2) as necessary. 4. Tighten the tie rod jam nut (1) to 127 Nm (94 ft. lbs.). 5. Verify the specifications 6. Turn off engine. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber And Caster Adjustment > Page 12594 Alignment: Service and Repair Camber, Caster And Toe Adjustment CAMBER, CASTER AND TOE ADJUSTMENT Camber and caster angle adjustments involve changing the position of the lower control arm with the slots in the frame brackets (1). CASTER Moving the front or rear position of the lower control arm in or out, will change the caster angle and camber angle significantly. To maintain the camber angle while adjusting caster, move one pivot bolt of the lower control arm in or out. Then move the other pivot bolt of the lower control arm in the opposite direction. To increase positive caster angle, move the rear position of the lower control arm inward (toward the engine). Move the front of the lower control arm outward (away from the engine) slightly until the desired camber angle is obtained. CAMBER Move both pivot bolts of the lower control arm together in or out. This will change the camber angle significantly and little effect on the caster angle. After adjustment is made tighten the lower control arm nuts to proper torque specification. TOE ADJUSTMENT The wheel toe position adjustment is the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. 2. Loosen the tie rod jam nuts (1). NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber And Caster Adjustment > Page 12595 3. Adjust the wheel toe position by turning the inner tie rod (2) as necessary. 4. Tighten the tie rod jam nut (1) to 127 Nm (94 ft. lbs.). 5. Verify the specifications 6. Turn off engine. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber And Caster Adjustment > Page 12596 Alignment: Service and Repair Alignment Link/Coil Suspension ALIGNMENT LINK/COIL SUSPENSION Before each alignment reading the vehicle should be jounced (rear first, then front). Grasp each bumper at the center and jounce the vehicle up and down several times. Always release the bumper in the down position. Set the front end alignment to specifications while the vehicle is in its NORMALLY LOADED CONDITION. CAMBER: The wheel camber angle is preset and is not adjustable. CASTER: Check the caster of the front axle for correct angle. Be sure the axle is not bent or twisted. Road test the vehicle and make left and right turn. Observe the steering wheel return-to-center position. Low caster will cause poor steering wheel returnability. Caster can be adjusted by rotating the cams (3) on the lower suspension arm. TOE POSITION: The wheel toe position adjustment should be the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Center and Secure the steering wheel and turn off engine. 2. Loosen the adjustment sleeve clamp bolts. 3. Adjust the right wheel toe position with the drag link. Turn the sleeve until the right wheel is at the correct TOE-IN position. Position clamp bolts to their original position and tighten to specifications. Make sure the toe setting does not change during clamp tightening. 4. Adjust left wheel toe position with tie rod at left knuckle. Turn the sleeve until the left wheel is at the correct TOE-IN position. Position clamp bolts to their original position and tighten to specifications. Make sure the toe setting does not change during clamp tightening. NOTE: Toe setting will change during tightening, Make sure to verify reading after tightening. 5. Verify the right toe setting and a straight steering wheel. 6. Road test the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber And Caster Adjustment > Page 12597 Alignment: Service and Repair Curb Height Measurement (HD) CURB HEIGHT MEASUREMENT (HD) The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load. Inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring is weak. 1. Front 4X2 On each side of the vehicle, measure the distance from the top of the jounce bumper flange (2) to the bottom of the frame rail (1). 2. Front 4X4 On each side of the vehicle, measure the distance from the top of the axle (2) to the bottom of the jounce bumper flange (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber And Caster Adjustment > Page 12598 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber And Caster Adjustment > Page 12599 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations Steering Mounted Controls Communication Module: Locations Component ID: 212 Component : MODULE-STEERING CONTROL Connector: Name : MODULE-STEERING CONTROL C1 Color : WHITE # of pins : 6 Pin Description Circuit 1 GROUND Z909 20BK 2 RADIO CONTROL MUX X20 20GY/WT 3 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 4 S/C SWITCH NO. 1 SIGNAL V37 20VT 5 S/C SWITCH RETURN V937 20VT/BR 6 HORN SWITCH SENSE X3 20DG/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12605 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12606 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12607 Connector: Name : MODULE-STEERING CONTROL C2 Color : BLACK # of pins : 2 Qualifier : (PREMIUM) Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12608 2 RADIO CONTROL MUX X20 22GY/WT 2 RADIO CONTROL MUX X20 22GY/WT Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12609 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12610 Connector: Name : MODULE-STEERING CONTROL C3 Color : # of pins : 4 Pin Description Circuit 1 HORN SWITCH SENSE X3 20DG/VT 2 S/C SWITCH RETURN V937 22DB/DG 2 SENSOR GROUND K900 22DB/DG 3 S/C SWITCH NO. 1 SIGNAL V37 22VT 4 S/C SWITCH NO. 2 SIGNAL V38 22VT/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12611 Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12612 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12613 Connector: Name : MODULE-STEERING CONTROL C4 Color : YELLOW # of pins : 4 Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R61 20LG/VT 2 DRIVER SQUIB 2 LINE 2 R63 20LG/WT 3 DRIVER SQUIB 1 LINE 1 R43 20LG/BR 4 DRIVER SQUIB 1 LINE 2 R45 20LG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12614 Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12615 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12616 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12617 Steering Mounted Controls Communication Module: Diagrams Component ID: 212 Component : MODULE-STEERING CONTROL Connector: Name : MODULE-STEERING CONTROL C1 Color : WHITE # of pins : 6 Pin Description Circuit 1 GROUND Z909 20BK 2 RADIO CONTROL MUX X20 20GY/WT 3 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 4 S/C SWITCH NO. 1 SIGNAL V37 20VT 5 S/C SWITCH RETURN V937 20VT/BR 6 HORN SWITCH SENSE X3 20DG/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12618 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12619 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12620 Connector: Name : MODULE-STEERING CONTROL C2 Color : BLACK # of pins : 2 Qualifier : (PREMIUM) Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12621 2 RADIO CONTROL MUX X20 22GY/WT 2 RADIO CONTROL MUX X20 22GY/WT Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12622 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12623 Connector: Name : MODULE-STEERING CONTROL C3 Color : # of pins : 4 Pin Description Circuit 1 HORN SWITCH SENSE X3 20DG/VT 2 S/C SWITCH RETURN V937 22DB/DG 2 SENSOR GROUND K900 22DB/DG 3 S/C SWITCH NO. 1 SIGNAL V37 22VT 4 S/C SWITCH NO. 2 SIGNAL V38 22VT/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12624 Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12625 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12626 Connector: Name : MODULE-STEERING CONTROL C4 Color : YELLOW # of pins : 4 Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R61 20LG/VT 2 DRIVER SQUIB 2 LINE 2 R63 20LG/WT 3 DRIVER SQUIB 1 LINE 1 R43 20LG/BR 4 DRIVER SQUIB 1 LINE 2 R45 20LG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12627 Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12628 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12629 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Description Power Steering Pressure Switch: Description and Operation Description DESCRIPTION A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will only be used on HD vehicles with the 5.7L engines. There is no pressure switch used for the 3.7L, 4.7L, 5.9LDiesel engine or the 5.7L LD vehicle pump. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Description > Page 12636 Power Steering Pressure Switch: Description and Operation Operation OPERATION The switch is used on the 5.7L V-8 engines HD vehicles only. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set Steering Angle Sensor: Customer Interest ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set NUMBER: 08-044-06 GROUP: Electrical DATE: October 07, 2006 SUBJECT: DTC C1240 - Steering Angle Sensor Over Travel Performance OVERVIEW: This bulletin involves the diagnosis and possible replacement of the Steering Angle Sensor. MODELS: 2007 (DR) Ram Truck NOTE: This bulletin applies to vehicle equipped with the Electronic Stability Program (sales code BNB) and built prior to October 03, 2006 (MDH 1003XX). SYMPTOM/CONDITION: The customer may experience an illumination on the instrument cluster of the "ABS" (Anti-Lock Brake System) and/or the "ESP / BAS" (Electronic Stability Program / Brake Assist System) Warning Lights. Investigation may reveal the presence of Diagnostic Trouble Code (DTC) C1240 Steering Angle Sensor Over Travel Performance (SAS). DIAGNOSIS: 1. Perform the diagnostic test procedure for DTC C1240. This diagnostic procedure can be found on TechCONNECT: select the SERVICE INFO tab > 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 340/445E5P AWAL > DIAGNOSIS and TESTING > C1240 - Steering Angle Sensor Over Travel Performance (SAS). 2. If the diagnostic test procedure for DTC C1240 determines that the Steering Angle Sensor is at fault, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Before starting this procedure, be certain that the front wheels are in the straight-ahead position. 1. Replace the steering column clockspring. Refer to TechCONNECT for detailed service procedures: select the SERVICE INFO tab > 8 - ELECTRICAL > RESTRAINTS > CLOCKSPRING > REMOVAL and INSTALLATION. 2. Clear offsets by initializing the ABS ECU using StarSCAN. 3. Perform the ABS VERIFICATION TEST. This test can be found in: 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 3401445E5P AWAL > STANDARD PROCEDURE > ABS VERIFICATION TEST. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set > Page 12645 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set Steering Angle Sensor: All Technical Service Bulletins ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set NUMBER: 08-044-06 GROUP: Electrical DATE: October 07, 2006 SUBJECT: DTC C1240 - Steering Angle Sensor Over Travel Performance OVERVIEW: This bulletin involves the diagnosis and possible replacement of the Steering Angle Sensor. MODELS: 2007 (DR) Ram Truck NOTE: This bulletin applies to vehicle equipped with the Electronic Stability Program (sales code BNB) and built prior to October 03, 2006 (MDH 1003XX). SYMPTOM/CONDITION: The customer may experience an illumination on the instrument cluster of the "ABS" (Anti-Lock Brake System) and/or the "ESP / BAS" (Electronic Stability Program / Brake Assist System) Warning Lights. Investigation may reveal the presence of Diagnostic Trouble Code (DTC) C1240 Steering Angle Sensor Over Travel Performance (SAS). DIAGNOSIS: 1. Perform the diagnostic test procedure for DTC C1240. This diagnostic procedure can be found on TechCONNECT: select the SERVICE INFO tab > 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 340/445E5P AWAL > DIAGNOSIS and TESTING > C1240 - Steering Angle Sensor Over Travel Performance (SAS). 2. If the diagnostic test procedure for DTC C1240 determines that the Steering Angle Sensor is at fault, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Before starting this procedure, be certain that the front wheels are in the straight-ahead position. 1. Replace the steering column clockspring. Refer to TechCONNECT for detailed service procedures: select the SERVICE INFO tab > 8 - ELECTRICAL > RESTRAINTS > CLOCKSPRING > REMOVAL and INSTALLATION. 2. Clear offsets by initializing the ABS ECU using StarSCAN. 3. Perform the ABS VERIFICATION TEST. This test can be found in: 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 3401445E5P AWAL > STANDARD PROCEDURE > ABS VERIFICATION TEST. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set > Page 12651 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set Steering Angle Sensor: Customer Interest ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set NUMBER: 08-044-06 GROUP: Electrical DATE: October 07, 2006 SUBJECT: DTC C1240 - Steering Angle Sensor Over Travel Performance OVERVIEW: This bulletin involves the diagnosis and possible replacement of the Steering Angle Sensor. MODELS: 2007 (DR) Ram Truck NOTE: This bulletin applies to vehicle equipped with the Electronic Stability Program (sales code BNB) and built prior to October 03, 2006 (MDH 1003XX). SYMPTOM/CONDITION: The customer may experience an illumination on the instrument cluster of the "ABS" (Anti-Lock Brake System) and/or the "ESP / BAS" (Electronic Stability Program / Brake Assist System) Warning Lights. Investigation may reveal the presence of Diagnostic Trouble Code (DTC) C1240 Steering Angle Sensor Over Travel Performance (SAS). DIAGNOSIS: 1. Perform the diagnostic test procedure for DTC C1240. This diagnostic procedure can be found on TechCONNECT: select the SERVICE INFO tab > 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 340/445E5P AWAL > DIAGNOSIS and TESTING > C1240 - Steering Angle Sensor Over Travel Performance (SAS). 2. If the diagnostic test procedure for DTC C1240 determines that the Steering Angle Sensor is at fault, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Before starting this procedure, be certain that the front wheels are in the straight-ahead position. 1. Replace the steering column clockspring. Refer to TechCONNECT for detailed service procedures: select the SERVICE INFO tab > 8 - ELECTRICAL > RESTRAINTS > CLOCKSPRING > REMOVAL and INSTALLATION. 2. Clear offsets by initializing the ABS ECU using StarSCAN. 3. Perform the ABS VERIFICATION TEST. This test can be found in: 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 3401445E5P AWAL > STANDARD PROCEDURE > ABS VERIFICATION TEST. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set > Page 12661 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set Steering Angle Sensor: All Technical Service Bulletins ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set NUMBER: 08-044-06 GROUP: Electrical DATE: October 07, 2006 SUBJECT: DTC C1240 - Steering Angle Sensor Over Travel Performance OVERVIEW: This bulletin involves the diagnosis and possible replacement of the Steering Angle Sensor. MODELS: 2007 (DR) Ram Truck NOTE: This bulletin applies to vehicle equipped with the Electronic Stability Program (sales code BNB) and built prior to October 03, 2006 (MDH 1003XX). SYMPTOM/CONDITION: The customer may experience an illumination on the instrument cluster of the "ABS" (Anti-Lock Brake System) and/or the "ESP / BAS" (Electronic Stability Program / Brake Assist System) Warning Lights. Investigation may reveal the presence of Diagnostic Trouble Code (DTC) C1240 Steering Angle Sensor Over Travel Performance (SAS). DIAGNOSIS: 1. Perform the diagnostic test procedure for DTC C1240. This diagnostic procedure can be found on TechCONNECT: select the SERVICE INFO tab > 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 340/445E5P AWAL > DIAGNOSIS and TESTING > C1240 - Steering Angle Sensor Over Travel Performance (SAS). 2. If the diagnostic test procedure for DTC C1240 determines that the Steering Angle Sensor is at fault, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Before starting this procedure, be certain that the front wheels are in the straight-ahead position. 1. Replace the steering column clockspring. Refer to TechCONNECT for detailed service procedures: select the SERVICE INFO tab > 8 - ELECTRICAL > RESTRAINTS > CLOCKSPRING > REMOVAL and INSTALLATION. 2. Clear offsets by initializing the ABS ECU using StarSCAN. 3. Perform the ABS VERIFICATION TEST. This test can be found in: 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 3401445E5P AWAL > STANDARD PROCEDURE > ABS VERIFICATION TEST. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set > Page 12667 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Diagrams Suspension Mode Switch: Diagrams Component ID: 461 Component : SWITCH-DISCONNECTING STABILIZER BAR Connector: Name : SWITCH-DISCONNECTING STABILIZER BAR Color : BLACK # of pins : 12 Pin Description Circuit 1 LOCKER SWITCH SUPPLY T537 20YL/LG 2 LOCKER SWITCH SENSE T535 20YL/BR 3 STABILIZER BAR SWITCH SENSE T531 20YL/TN 4 SWITCH SUPPLY T536 20YL/WT 5 LOCKER OPEN ILLUMINATION SENSE T532 20YL/GY 6 LOCKER REAR ILLUMINATION SENSE T533 20YL/LB 7 LOCKER FR/RR ILLUMINATION SENSE T534 20YL 8 STABILIZER BAR DISENGAGE ILLUMINATION SENSE T530 20YL/DG 9 STABILIZER BAR ENGAGE ILLUMINATION SENSE T529 20YL/LG 10 - 11 PANEL LAMPS DRIVER E11 20OR/DB 12 GROUND Z952 20BK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > Recalls for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects Technical Service Bulletin # H46 Date: 090609 Recall - Steering Linkage Defects Revised May 2009 Dealer Service Instructions for: Safety Recall H46 - Mopar Steering Linkage NOTE: The service procedure for this recall has been revised and additional labor operations have been added. All previous copies of Safety Recall H46 should be discarded from your files. Models 2003-2004 (DR) Dodge Truck 4x4 (2500/3500 series) 2005 (DH) Dodge Truck 4x4 (2500/3500 series) 2006-2009 (DH) Dodge Truck 4x4 (2500/3500 series or 1500 Mega Cab) 2006-2009 (D1) Dodge Truck 4x4 (3500 series) 2007-2009 (DC) Dodge Truck (3500 series cab chassis) IMPORTANT: This recall only applies to vehicles that had certain Mopar service parts steering components installed. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject During a prior service appointment, a Mopar service parts steering linkage was installed on about 19,400 of the above vehicles. The drag link inner joint may fracture under certain driving conditions. This could result in a loss of steering control and cause a crash without warning. Also, the steering damper bracket at the tie rod tube may loosen. This could allow the bracket to slide on the tube and may cause increased vehicle turning radius. Repair The steering linkage must be inspected and some steering linkage components may need to be replaced. NOTE: The initial steering linkage inspection process can be done by write up personnel in the write up area (see Step 1 of the service procedure). Vehicles found with original style steering linkage can be immediately returned to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > Recalls for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12680 Parts Information Special Tools The special tools may be required to perform this repair: Completion Reporting and Reimbursement Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > Recalls for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12681 Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. FOR VEHICLES INSPECTED IN THE WRITE UP AREA: Enter "INSPECT" in the part number section of your claim with a quantity of one (1). Enter $5.00 WITH NO MARK-UP for reimbursement of steering linkage inspection performed in the write up area. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > Recalls for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12682 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure NOTE: The initial steering linkage inspection process (Step 1 of the service procedure) can be done by write up personnel in the write up area. Vehicles found with the steering linkage shown in Figure 1 can be immediately returned to the customer. See the "Completion Reporting and Reimbursement" section of this recall for special claims processing information. 1. Look under the front of the vehicle and inspect the steering linkage at the steering damper mounting point: > If the steering damper mounts to the tie rod tube as shown in Figure 1, the steering linkage is good. Return the vehicle to the customer. No further action is required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > Recalls for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12683 > If the steering damper mounts to the tie rod tube as shown in Figure 2, the vehicle will require further inspection and/or repair by a technician. The vehicle should be assigned to a technician and the technician should continue with Step 2 of this procedure. 2. Lift the vehicle on a hoist and inspect the steering linkage drag link for a white part number tag (Figure 3): > If the steering linkage drag link does not have a white part number tag, continue with Step 3 of this procedure. ^ If the steering linkage drag link has a white part number tag: > For 2009 model year trucks, continue with Step 9 of this procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > Recalls for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12684 > For 2003 through 2008 model year trucks, continue with Step 5 of this procedure. 3. Inspect the steering damper bracket to tie rod tube mounting u-bolt nuts by putting a 13 mm box-end wrench onto the nut (Figure 4): > If a 13 mm wrench fits the steering damper bracket mounting u-bolt nuts, the bracket and fasteners must be replaced. Continue with Step 4 of this procedure. > If a 13 mm wrench does not fit the steering damper bracket mounting u-bolt nuts, the bracket does not require replacement. Continue with Step 5 of this procedure. 4. Replace the steering damper bracket and fasteners using the following procedure: a. Remove and save the steering damper-to-damper bracket mounting nut (Figure 5). b. Disconnect the steering damper eyelet from the steering damper bracket. c. Remove and discard the four steering damper bracket nuts, two u-bolts and the steering damper bracket (Figure 5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > Recalls for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12685 d. Place the new steering damper carriage bolt through the square hole in the new steering damper bracket. e. Place the new steering damper bracket assembly onto the tie rod tube at the flat spot area on the tube and install the new u-bolts and nuts. Lightly snug the nuts to hold the steering damper bracket in position. f. Center the new steering damper bracket on the flattened area of the tie rod tube. g. Evenly tighten the four steering damper bracket u-bolt nuts to 25 ft. lbs. (34 N.m). Then tighten the four u-bolt nuts to 45 ft. lbs. (61 N.m). h. Connect the steering damper to the steering damper carriage bolt. i. Install the steering damper-to-damper bracket mounting nut and tighten to 75 ft. lbs. (100 N.m). j. Continue with Step 5 of this procedure. 5. For 2009 model year trucks, continue with Step 6 of this procedure. For 2003 through 2008 model year trucks, inspect the pitman arm part number (Figure 6): > If the part number cast into the bottom side of the pitman arm is 68039930AA the pitman arm does not require replacement. > Steering linkage with a white part number tag, continue with Step 9 of this procedure. > Linkage without a white part number tag, replace the inner drag link joint. Continue with Step 6 of this procedure. > If the part number cast into the bottom side of the pitman arm is 52106836AB, or is not legible: > Steering linkage without a white part number tag, replace the inner drag link joint and pitman arm. Continue with Step 7 of this procedure. > Steering linkage with a white part number tag, replace the pitman arm. Continue with Step 8 of this procedure. 6. Replace the inner drag link joint using the following procedure: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > Recalls for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12686 a. Loosen both drag link adjuster sleeve clamp nuts (Figure 7). b. Remove and discard the inner drag link joint to pitman arm nut (Figure 7). c. Use Special Tool C-4150A to separate the steering inner drag link joint from the pitman arm (Figure 8). d. While counting the number of turns, unscrew the steering inner drag link joint from the drag link adjuster sleeve (right handed threads) and discard the drag link inner joint. CAUTION: Do not allow the drag link adjuster sleeve to turn while unscrewing the inner drag link joint. e. Screw in the new inner drag link joint into the drag link adjuster sleeve the same number of turns counted in step 6d. of this procedure. f. Connect the steering inner drag link joint to the pitman arm. g. Install the new steering inner drag link joint nut and tighten the nut to 100 ft. lbs. (135 N.m). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > Recalls for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12687 h. With the wheels in the straight ahead position, make sure that both inner and outer steering drag link joint caps are centered over the joint ball stud (Figure 9). CAUTION: Failure to center the drag link inner and outer joint caps over the joint ball studs before tightening the drag link adjuster sleeve clamps could cause joint failure. i. With the adjuster sleeve clamps rotated 45 degrees forward, tighten both drag link adjuster sleeve clamp nuts to 45 ft. lbs. (61 N.m). CAUTION: The drag link adjuster sleeve clamp tabs must be pointing approximately 45 degrees forward before tightening (as shown in Figure 10). Do not allow the adjuster sleeve clamp tabs to hang straight down. j. Lower the vehicle from the hoist. k. Drive the vehicle to verify that the steering wheel is straight. > If the steering wheel is turned to the left, shorten the drag link at the adjuster sleeve located on the drag link. > If the steering wheel is turned to the right, lengthen the drag link at the adjuster sleeve located on the drag link. l. Repeat Step 6k. until steering wheel is straight. m. Continue with Step 9 of this procedure. 7. Replace the inner drag link joint and pitman arm using the following procedure: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > Recalls for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12688 a. Loosen both drag link adjuster sleeve clamp nuts (Figure 7). b. Remove and save the pitman arm retaining nut located on the steering gear output shaft. c. Install pitman arm puller (Special Tool 9615) onto the steering gear output shaft (Figure 11). CAUTION: Failure to use the correct pitman arm puller could cause damage to the steering gear. d. Tighten the pitman arm puller forcing screw until the pitman arm separates from the steering gear output shaft (Figure 11). e. While counting the number of turns, unscrew the steering inner drag link joint (with pitman arm still attached) from the drag link adjuster sleeve (right handed threads) and discard the pitman arm and inner drag link joint. CAUTION: Do not allow the drag link adjuster sleeve to turn while unscrewing the inner drag link joint. f. Screw in the new steering inner drag link joint into the drag link adjuster sleeve the same number of turns counted in step 7e. of this procedure. g. Install the new pitman arm and retaining nut onto the steering gear output shaft. Tighten the pitman arm nut to 225 ft. lbs. (300 N.m). h. Connect the steering inner drag link joint to the pitman arm. i. Install the new steering inner drag link joint nut and tighten the nut to 100 ft. lbs. (135 N.m). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > Recalls for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12689 j. With the wheels in the straight ahead position, make sure that both inner and outer steering drag link joint caps are centered over the joint ball stud (Figure 12). CAUTION: Failure to center the drag link inner and outer joint caps over the joint ball studs before tightening the drag link adjuster sleeve clamps could cause joint failure. k. With the adjuster sleeve clamps rotated 45 degrees forward, tighten the drag link adjuster sleeve clamp nuts to 45 ft. lbs. (61 N.m).lbs. CAUTION: The drag link adjuster sleeve clamp tabs must be pointing approximately 45 degrees forward before tightening (as shown in Figure 10). Do not allow the adjuster sleeve clamp tabs to hang straight down. l. Lower the vehicle from the hoist. m. Drive the vehicle to verify that the steering wheel is straight. > If the steering wheel is turned to the left, shorten the drag link at the adjuster sleeve located on the drag link. > If the steering wheel is turned to the right, lengthen the drag link at the adjuster sleeve located on the drag link. n. Repeat Step 7m. until steering wheel is straight. o. Continue with Step 9 of this procedure. 8. Replace the pitman arm using the following procedure: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > Recalls for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12690 a. Remove and discard the inner drag link joint nut (Figure 13). b. Use Special Tool C-4150A to separate the steering inner drag link joint from the pitman arm (Figure 14). CAUTION: Use extreme care not to tear, nick or damage the inner drag link joint rubber boot. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > Recalls for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12691 d. Install pitman arm puller (Special Tool 9615) onto the steering gear output shaft (Figure 15). CAUTION: Failure to use the correct pitman arm puller could cause damage to the steering gear. e. Tighten the pitman arm puller forcing screw until the pitman arm separates from the steering gear output shaft (Figure 15). f. Install the new pitman arm. g. Install the pitman arm retaining nut onto the steering gear output shaft. Tighten the pitman arm nut to 225 ft. lbs. (300 N.m). h. Connect the steering inner drag link joint to the pitman arm. i. Install the new steering inner drag link joint nut and tighten the nut to 100 ft. lbs. (135 N.m). j. Lower the vehicle from the hoist. k. Drive the vehicle to verify that the steering wheel is straight. > If the steering wheel is turned to the left, shorten the drag link at the adjuster sleeve located on the drag link. ^ If the steering wheel is turned to the right, lengthen the drag link at the adjuster sleeve located on the drag link. l. Repeat Step 8k. until steering wheel is straight. m. Continue with Step 9 of this procedure. 9. Verify the lower surface of the left outer tie rod socket is parallel to the upper surface of the left knuckle attaching arm using the following procedure: a. Loosen the tie rod tube adjuster sleeve clamps. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > Recalls for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12692 b. Rotate the left tie rod until the bottom of the tie rod socket is parallel to the top of the left steering knuckle arm (Figure 16). c. Tighten the tie rod adjuster sleeve clamp nuts to 45 ft.lbs. (61 N.m). CAUTION: Failure to align the left tie rod end parallel to the steering knuckle could cause tie rod end damage. d. Return the vehicle to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > Recalls for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12693 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects Technical Service Bulletin # H46 Date: 090609 Recall - Steering Linkage Defects Revised May 2009 Dealer Service Instructions for: Safety Recall H46 - Mopar Steering Linkage NOTE: The service procedure for this recall has been revised and additional labor operations have been added. All previous copies of Safety Recall H46 should be discarded from your files. Models 2003-2004 (DR) Dodge Truck 4x4 (2500/3500 series) 2005 (DH) Dodge Truck 4x4 (2500/3500 series) 2006-2009 (DH) Dodge Truck 4x4 (2500/3500 series or 1500 Mega Cab) 2006-2009 (D1) Dodge Truck 4x4 (3500 series) 2007-2009 (DC) Dodge Truck (3500 series cab chassis) IMPORTANT: This recall only applies to vehicles that had certain Mopar service parts steering components installed. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject During a prior service appointment, a Mopar service parts steering linkage was installed on about 19,400 of the above vehicles. The drag link inner joint may fracture under certain driving conditions. This could result in a loss of steering control and cause a crash without warning. Also, the steering damper bracket at the tie rod tube may loosen. This could allow the bracket to slide on the tube and may cause increased vehicle turning radius. Repair The steering linkage must be inspected and some steering linkage components may need to be replaced. NOTE: The initial steering linkage inspection process can be done by write up personnel in the write up area (see Step 1 of the service procedure). Vehicles found with original style steering linkage can be immediately returned to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12699 Parts Information Special Tools The special tools may be required to perform this repair: Completion Reporting and Reimbursement Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12700 Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. FOR VEHICLES INSPECTED IN THE WRITE UP AREA: Enter "INSPECT" in the part number section of your claim with a quantity of one (1). Enter $5.00 WITH NO MARK-UP for reimbursement of steering linkage inspection performed in the write up area. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12701 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure NOTE: The initial steering linkage inspection process (Step 1 of the service procedure) can be done by write up personnel in the write up area. Vehicles found with the steering linkage shown in Figure 1 can be immediately returned to the customer. See the "Completion Reporting and Reimbursement" section of this recall for special claims processing information. 1. Look under the front of the vehicle and inspect the steering linkage at the steering damper mounting point: > If the steering damper mounts to the tie rod tube as shown in Figure 1, the steering linkage is good. Return the vehicle to the customer. No further action is required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12702 > If the steering damper mounts to the tie rod tube as shown in Figure 2, the vehicle will require further inspection and/or repair by a technician. The vehicle should be assigned to a technician and the technician should continue with Step 2 of this procedure. 2. Lift the vehicle on a hoist and inspect the steering linkage drag link for a white part number tag (Figure 3): > If the steering linkage drag link does not have a white part number tag, continue with Step 3 of this procedure. ^ If the steering linkage drag link has a white part number tag: > For 2009 model year trucks, continue with Step 9 of this procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12703 > For 2003 through 2008 model year trucks, continue with Step 5 of this procedure. 3. Inspect the steering damper bracket to tie rod tube mounting u-bolt nuts by putting a 13 mm box-end wrench onto the nut (Figure 4): > If a 13 mm wrench fits the steering damper bracket mounting u-bolt nuts, the bracket and fasteners must be replaced. Continue with Step 4 of this procedure. > If a 13 mm wrench does not fit the steering damper bracket mounting u-bolt nuts, the bracket does not require replacement. Continue with Step 5 of this procedure. 4. Replace the steering damper bracket and fasteners using the following procedure: a. Remove and save the steering damper-to-damper bracket mounting nut (Figure 5). b. Disconnect the steering damper eyelet from the steering damper bracket. c. Remove and discard the four steering damper bracket nuts, two u-bolts and the steering damper bracket (Figure 5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12704 d. Place the new steering damper carriage bolt through the square hole in the new steering damper bracket. e. Place the new steering damper bracket assembly onto the tie rod tube at the flat spot area on the tube and install the new u-bolts and nuts. Lightly snug the nuts to hold the steering damper bracket in position. f. Center the new steering damper bracket on the flattened area of the tie rod tube. g. Evenly tighten the four steering damper bracket u-bolt nuts to 25 ft. lbs. (34 N.m). Then tighten the four u-bolt nuts to 45 ft. lbs. (61 N.m). h. Connect the steering damper to the steering damper carriage bolt. i. Install the steering damper-to-damper bracket mounting nut and tighten to 75 ft. lbs. (100 N.m). j. Continue with Step 5 of this procedure. 5. For 2009 model year trucks, continue with Step 6 of this procedure. For 2003 through 2008 model year trucks, inspect the pitman arm part number (Figure 6): > If the part number cast into the bottom side of the pitman arm is 68039930AA the pitman arm does not require replacement. > Steering linkage with a white part number tag, continue with Step 9 of this procedure. > Linkage without a white part number tag, replace the inner drag link joint. Continue with Step 6 of this procedure. > If the part number cast into the bottom side of the pitman arm is 52106836AB, or is not legible: > Steering linkage without a white part number tag, replace the inner drag link joint and pitman arm. Continue with Step 7 of this procedure. > Steering linkage with a white part number tag, replace the pitman arm. Continue with Step 8 of this procedure. 6. Replace the inner drag link joint using the following procedure: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12705 a. Loosen both drag link adjuster sleeve clamp nuts (Figure 7). b. Remove and discard the inner drag link joint to pitman arm nut (Figure 7). c. Use Special Tool C-4150A to separate the steering inner drag link joint from the pitman arm (Figure 8). d. While counting the number of turns, unscrew the steering inner drag link joint from the drag link adjuster sleeve (right handed threads) and discard the drag link inner joint. CAUTION: Do not allow the drag link adjuster sleeve to turn while unscrewing the inner drag link joint. e. Screw in the new inner drag link joint into the drag link adjuster sleeve the same number of turns counted in step 6d. of this procedure. f. Connect the steering inner drag link joint to the pitman arm. g. Install the new steering inner drag link joint nut and tighten the nut to 100 ft. lbs. (135 N.m). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12706 h. With the wheels in the straight ahead position, make sure that both inner and outer steering drag link joint caps are centered over the joint ball stud (Figure 9). CAUTION: Failure to center the drag link inner and outer joint caps over the joint ball studs before tightening the drag link adjuster sleeve clamps could cause joint failure. i. With the adjuster sleeve clamps rotated 45 degrees forward, tighten both drag link adjuster sleeve clamp nuts to 45 ft. lbs. (61 N.m). CAUTION: The drag link adjuster sleeve clamp tabs must be pointing approximately 45 degrees forward before tightening (as shown in Figure 10). Do not allow the adjuster sleeve clamp tabs to hang straight down. j. Lower the vehicle from the hoist. k. Drive the vehicle to verify that the steering wheel is straight. > If the steering wheel is turned to the left, shorten the drag link at the adjuster sleeve located on the drag link. > If the steering wheel is turned to the right, lengthen the drag link at the adjuster sleeve located on the drag link. l. Repeat Step 6k. until steering wheel is straight. m. Continue with Step 9 of this procedure. 7. Replace the inner drag link joint and pitman arm using the following procedure: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12707 a. Loosen both drag link adjuster sleeve clamp nuts (Figure 7). b. Remove and save the pitman arm retaining nut located on the steering gear output shaft. c. Install pitman arm puller (Special Tool 9615) onto the steering gear output shaft (Figure 11). CAUTION: Failure to use the correct pitman arm puller could cause damage to the steering gear. d. Tighten the pitman arm puller forcing screw until the pitman arm separates from the steering gear output shaft (Figure 11). e. While counting the number of turns, unscrew the steering inner drag link joint (with pitman arm still attached) from the drag link adjuster sleeve (right handed threads) and discard the pitman arm and inner drag link joint. CAUTION: Do not allow the drag link adjuster sleeve to turn while unscrewing the inner drag link joint. f. Screw in the new steering inner drag link joint into the drag link adjuster sleeve the same number of turns counted in step 7e. of this procedure. g. Install the new pitman arm and retaining nut onto the steering gear output shaft. Tighten the pitman arm nut to 225 ft. lbs. (300 N.m). h. Connect the steering inner drag link joint to the pitman arm. i. Install the new steering inner drag link joint nut and tighten the nut to 100 ft. lbs. (135 N.m). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12708 j. With the wheels in the straight ahead position, make sure that both inner and outer steering drag link joint caps are centered over the joint ball stud (Figure 12). CAUTION: Failure to center the drag link inner and outer joint caps over the joint ball studs before tightening the drag link adjuster sleeve clamps could cause joint failure. k. With the adjuster sleeve clamps rotated 45 degrees forward, tighten the drag link adjuster sleeve clamp nuts to 45 ft. lbs. (61 N.m).lbs. CAUTION: The drag link adjuster sleeve clamp tabs must be pointing approximately 45 degrees forward before tightening (as shown in Figure 10). Do not allow the adjuster sleeve clamp tabs to hang straight down. l. Lower the vehicle from the hoist. m. Drive the vehicle to verify that the steering wheel is straight. > If the steering wheel is turned to the left, shorten the drag link at the adjuster sleeve located on the drag link. > If the steering wheel is turned to the right, lengthen the drag link at the adjuster sleeve located on the drag link. n. Repeat Step 7m. until steering wheel is straight. o. Continue with Step 9 of this procedure. 8. Replace the pitman arm using the following procedure: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12709 a. Remove and discard the inner drag link joint nut (Figure 13). b. Use Special Tool C-4150A to separate the steering inner drag link joint from the pitman arm (Figure 14). CAUTION: Use extreme care not to tear, nick or damage the inner drag link joint rubber boot. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12710 d. Install pitman arm puller (Special Tool 9615) onto the steering gear output shaft (Figure 15). CAUTION: Failure to use the correct pitman arm puller could cause damage to the steering gear. e. Tighten the pitman arm puller forcing screw until the pitman arm separates from the steering gear output shaft (Figure 15). f. Install the new pitman arm. g. Install the pitman arm retaining nut onto the steering gear output shaft. Tighten the pitman arm nut to 225 ft. lbs. (300 N.m). h. Connect the steering inner drag link joint to the pitman arm. i. Install the new steering inner drag link joint nut and tighten the nut to 100 ft. lbs. (135 N.m). j. Lower the vehicle from the hoist. k. Drive the vehicle to verify that the steering wheel is straight. > If the steering wheel is turned to the left, shorten the drag link at the adjuster sleeve located on the drag link. ^ If the steering wheel is turned to the right, lengthen the drag link at the adjuster sleeve located on the drag link. l. Repeat Step 8k. until steering wheel is straight. m. Continue with Step 9 of this procedure. 9. Verify the lower surface of the left outer tie rod socket is parallel to the upper surface of the left knuckle attaching arm using the following procedure: a. Loosen the tie rod tube adjuster sleeve clamps. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12711 b. Rotate the left tie rod until the bottom of the tie rod socket is parallel to the top of the left steering knuckle arm (Figure 16). c. Tighten the tie rod adjuster sleeve clamp nuts to 45 ft.lbs. (61 N.m). CAUTION: Failure to align the left tie rod end parallel to the steering knuckle could cause tie rod end damage. d. Return the vehicle to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Link: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12712 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair > Removal Center Link: Service and Repair Removal REMOVAL 1. Remove the drag link nut (2) from the pitman arm side (1). 2. Remove the drag link nut from the knuckle side. 3. Remove the drag link (2) from the right knuckle and pitman arm (1) with Puller C-3894A (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair > Removal > Page 12715 Center Link: Service and Repair Installation INSTALLATION 1. Install the drag link (2) to the pitman arm (1). Install the nut and tighten to 88 Nm (65 ft. lbs.). 2. Install the drag link to the right steering knuckle. Install the nut and tighten to 54 Nm (40 ft. lbs.). Then an additional 90°. 3. Install tie rod to the left steering knuckle and drag link. Install the nuts and tighten to 54 Nm (40 ft. lbs.). Then an additional 90°. 4. Remove the supports and lower the vehicle to the surface. Center steering wheel and adjust toe. 5. After adjustment tighten tie rod adjustment sleeve clamp bolts to 61 Nm (45 ft. lbs.). NOTE: Position the clamp on the sleeve so retaining bolt is located on the bottom side of the sleeve. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation > Description Front Steering Knuckle: Description and Operation Description DESCRIPTION The knuckle (1) is a single casting with legs machined for the upper and lower ball joints. The knuckle also has machined mounting locations for the front brake calipers and hub bearing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation > Description > Page 12720 Front Steering Knuckle: Description and Operation Operation OPERATION The steering knuckle pivot between the upper and lower ball joint. Steering linkage attached to the knuckle allows the vehicle to be steered. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front - Independent Front Suspension Front Steering Knuckle: Service and Repair Front - Independent Front Suspension Removal (LD) 4X2 & 4X4 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, rotor, shield and ABS wheel speed sensor if equipped. 4. Remove the tie rod end nut. Separate the tie rod from the knuckle with Remover 9360. 5. Remove the halfshaft nut (4X4 only). 6. Remove the upper ball joint nut. Separate the ball joint (4) from the knuckle (6) with Remover 9360 (5) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front - Independent Front Suspension > Page 12723 CAUTION: When installing puller 8677 to separate the ball joint, be careful not to damage the ball joint seal. 7. Remove the lower ball joint nut. Separate the ball joint from the knuckle with Remover 8677 (2). 8. Remove the steering knuckle (1) from the vehicle. 9. Remove the hub/bearing from the steering knuckle on the bench. Installation (LD) 4X2 & 4X4 CAUTION: The ball joint stud tapers must be CLEAN and DRY before installing the knuckle. Clean the stud tapers with mineral spirits to remove dirt and grease. NOTE: When installing hub/bearing with ABS brakes, position the speed sensor opening towards the front of the vehicle. 1. Install the hub/bearing to the steering knuckle (1) and tighten the bolts to 163 Nm (120 ft. lbs.). 2. Install the knuckle (1) onto the upper and lower ball joints. 3. Install the upper and lower ball joint nuts. Tighten the upper ball joint nut to 54 Nm (40 ft. lbs.) (an additional 90° turn is required) and the lower ball joint nut to 52 Nm (38 ft. lbs.)(an additional 90° turn is required). 4. Remove the hydraulic jack from the lower suspension arm (4). 5. Install the tie rod end and tighten the nut to 61 Nm (45 ft. lbs.). 6. Install the front halfshaft into the hub/bearing (if equipped). 7. Install the the halfshaft nut and tighten to 251 Nm (185 ft. lbs.) (if equipped). 8. Install the ABS wheel speed sensor (if equipped) and brake shield, rotor and caliper. 9. Install the wheel and tire assembly. 10. Remove the support and lower the vehicle. 11. Perform a wheel alignmen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front - Independent Front Suspension > Page 12724 Front Steering Knuckle: Service and Repair Front - Link/Coil Removal REMOVAL 1. Remove the hub bearing. 2. Remove tie-rod or drag link end from the steering knuckle arm. 3. Remove the wheel speed sensor. 4. Loosen the upper ball stud nut.Do not remove the nut at this time. 5. Remove the lower ball joint nut. 6. Separate the lower ball joint (4) using special tool C-4150A separator (3). 7. Remove the upper ball joint nut. 8. Remove the steering knuckle (2). Installation INSTALLATION 1. Position the steering knuckle on the ball studs. 2. Install and tighten lower ball stud nut to 47 Nm (35 ft. lbs.) torque. 3. Install and tighten upper ball stud nut to 94 Nm (70 ft. lbs.) torque. 4. Retorque lower ball stud nut to 190-217 Nm (140-160 ft. lbs.) torque. 5. Install the hub bearing. 6. Install tie-rod or drag link end onto the steering knuckle arm. 7. Install the wheel speed sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Service and Repair > Removal Pitman Arm: Service and Repair Removal REMOVAL 1. Remove the drag link nut (2) from the pitman arm (1). 2. Install puller C-3894-A (3) and separate the drag link (2) from the pitman arm (1). 3. Mark the pitman arm (2) and shaft positions for installation reference. Remove the nut (3) and washer (4) from the pitman arm (2). 4. Remove the pitman arm (4) with Puller 9615 (2) or an equivalent pitman arm puller tool. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Service and Repair > Removal > Page 12729 Pitman Arm: Service and Repair Installation INSTALLATION 1. Align reference marks and install pitman arm. 2. Install the lock washer and retaining nut on the pitman shaft and tighten nut to 251 Nm (185 ft. lbs.). 3. Install the drag link (1) to the pitman arm (5). Install the nut (4) and tighten to 54 Nm (40 ft. lbs.). Then an additional 90°. 4. Remove the supports and lower the vehicle to the surface. Center steering wheel and adjust toe. 5. After adjustment tighten tie rod adjustment sleeve clamp bolts to 61 Nm (45 ft. lbs.). NOTE: Position the clamp on the sleeve so retaining bolt is located on the bottom side of the sleeve. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Power Steering Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 12735 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 12736 Power Steering Fluid: Specifications POWER STEERING FLUID Mopar ATF +4 Automatic Transmission Fluid. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 12737 Power Steering Fluid: Description and Operation DESCRIPTION NOTE: It is normal that some pressure will build up inside the reservoir, especially, with a warm vehicle. A slight popping noise upon removal of the cap is normal. The fluid level should read between the ADD and the FULL COLD marks. When the fluid is hot it should read between ADD and FULL HOT marks. Only add fluid when the vehicle is cold. The recommended fluid for the power steering system is Mopar(R) ATF +4. Mopar(R) ATF+4, when new is red in color. The ATF+4 is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition, As the vehicle is driven, the ATF+4 will begin to look darker in color and may eventually become brown. THIS IS NORMAL. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 12738 Power Steering Fluid: Testing and Inspection POWER STEERING FLUID LEVEL CHECKING WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS. CAUTION: MOPAR(R) ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill. The power steering fluid level can be viewed on the dipstick attached to the filler cap. There are two ranges listed on the dipstick, COLD and HOT. Before opening power steering system, wipe the reservoir filler cap free of dirt and debris. Remove the cap and check the fluid level on its dipstick. When the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F), the fluid level should read between the minimum and maximum area of the cold range. When the fluid is hot, fluid level is allowed to read up to the highest end of the HOT range. Only add fluid when the vehicle is cold. Use only Mopar(R) ATF+4. Do not overfill the power steering system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 12739 Power Steering Fluid: Service and Repair POWER STEERING SYSTEM BLEEDING WARNING: The fluid level should be checked with engine off to prevent injury from moving components. CAUTION: Mopar(R) Power Steering Fluid + 4 or Mopar(R) ATF+4 Automatic Transmission Fluid is to be used in the power steering system. Both Fluids have the same material standard specifications (MS-9602). No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if another fluid is used. Do not overfill the system. CAUTION: If the air is not purged from the power steering system correctly, pump failure could result. NOTE: Be sure the vacuum tool used in the following procedure is clean and free of any fluids. 1. Check the fluid level. As measured on the side of the reservoir, the level should indicate between MAX and MIN when the fluid is at normal ambient temperature. Adjust the fluid level as necessary. 2. Tightly insert Power Steering Cap Adapter (4), Special Tool 9688, into the mouth of the reservoir (3). CAUTION: Failure to use a the vacuum pump reservoir (1) may allow power steering fluid to be sucked into the hand vacuum pump. 3. Attach Hand Vacuum Pump (2), Special Tool C-4207 or equivalent, with reservoir (1) attached, to the Power Steering Cap Adapter (4). CAUTION: Do not run the engine while vacuum is applied to the power steering system. Damage to the power steering pump can occur. NOTE: When performing the following step make sure the vacuum level is maintained during the entire time period. 4. Using Hand Vacuum Pump (2), apply 68-85 kPa (20-25 in. Hg) of vacuum to the system for a minimum of three minutes. 5. Slowly release the vacuum and remove the special tools. 6. Adjust the fluid level as necessary. Refer to STEP 1. 7. Repeat STEP 1 through STEP 6 until the fluid no longer drops when vacuum is applied. 8. Start the engine and cycle the steering wheel lock-to-lock three times. NOTE: Do not hold the steering wheel at the stops. 9. Stop the engine and check for leaks at all connections. 10. Check for any signs of air in the reservoir and check the fluid level. If air is present, repeat the procedure as necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Removal Power Steering Fluid Cooler: Service and Repair Removal REMOVAL 1. Drain and siphon the power steering fluid. 2. Disconnect the return and supply hoses connected to the power steering fluid cooler. 3. Remove the mounting bracket bolts (2) securing the fluid cooler (1) to the brace. (V6&V8;) 4. Remove the mounting bracket bolts (3) securing the fluid cooler (1) to the brace. (Diesel engine) 5. Remove the fluid cooler from the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Removal > Page 12744 Power Steering Fluid Cooler: Service and Repair Installation INSTALLATION 1. Install the fluid cooler (1) to the vehicle. 2. Install the mounting bracket bolts (2) securing the fluid cooler (1) to the brace (V6&V8;). 3. Install the mounting bracket bolts (3) securing the fluid cooler (1) to the brace (Diesel Engine). 4. Reclamp the return and supply hoses to the power steering fluid cooler (4). 5. Refill the power steering fluid. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Removal Power Steering Fluid Reservoir: Service and Repair Removal REMOVAL 1. Drain and siphon the power steering fluid from the reservoir. 2. Remove the serpentine belt. 3. Remove the power steering pump. 4. Remove the reservoir mounting bolts. 5. Remove the reservoir. 6. Remove the rear bracket to the pump mounting bolts. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Removal > Page 12749 Power Steering Fluid Reservoir: Service and Repair Installation INSTALLATION 1. Install the reservoir bracket to the pump housing. Do not reuse the O-rings (install new O-rings). Tighten bolts to 7 Nm (62 in. lbs.). NOTE: Ensure the reservoir is fully seated onto the pump. 2. Install the reservoir to the bracket/pump body. 3. Install the reservoir mounting bolts. Tighten bolts to 13 Nm (120 in. lbs.). 4. Install the power steering pump. 5. Install the serpentine drive belt. 6. Fill the power steering pump. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hoses - I.F.S. Power Steering Line/Hose: Service and Repair Hoses - I.F.S. Return Hose - Gear To Cooler RETURN HOSE - GEAR TO COOLER 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the return hose at the cooler. 4. Disconnect the return hose (1) at the gear. 5. Remove the return hose from the routing clamp at the fan shroud and then remove from the vehicle. Pressure Hose PRESSURE HOSE 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the pressure hose at the pump. 4. Disconnect the pressure hose (2) at the gear. 5. Remove the pressure hose from the vehicle. Return Hose - Reservoir To Cooler RETURN HOSE - RESERVOIR TO COOLER 1. Drain and siphon the power steering system. 2. Disconnect the return hose at the reservoir. 3. Raise and support the vehicle. 4. Remove the return hose from the routing clamp at the fan shroud. 5. Disconnect the return hose at the cooler. 6. Remove the hose from the vehicle. Return Hose - Gear To Cooler Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hoses - I.F.S. > Page 12754 RETURN HOSE - GEAR TO COOLER 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reconnect the return hose (1) at the gear. Tighten the hose to 50 Nm (37 ft. lbs.). 4. Reattach the hose to the routing clip at the fan shroud. 5. Remove the support and lower the vehicle. 6. Refill the power steering system. Pressure Hose PRESSURE HOSE NOTE: Be sure to align the pressure hose so it does not contact the fan shroud or the frame rail. 1. Install the pressure hose to the vehicle. 2. Reconnect the pressure hose (2) at the gear. Tighten the hose to 32 Nm (23 ft. lbs.). 3. Reconnect the pressure hose at the pump. Tighten the hose to 31 Nm (23 ft. lbs.). 4. Remove the support and lower the vehicle. 5. Refill the power steering system. Return Hose - Reservoir To Cooler RETURN HOSE - RESERVOIR TO COOLER 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reattach the hose to the routing clip at the fan shroud. 4. Remove the support and lower the vehicle. 5. Reconnect the return hose at the reservoir. 6. Refill the power steering system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hoses - I.F.S. > Page 12755 Power Steering Line/Hose: Service and Repair Hoses - Link/Coil Return Hose - Gear To Cooler RETURN HOSE - GEAR TO COOLER 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the return hose at the cooler. 4. Disconnect the return hose (2) at the gear. 5. Remove the return hose from the routing clamp at the fan shroud and then remove from the vehicle. Pressure Hose PRESSURE HOSE 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the pressure hose at the pump. 4. Disconnect the pressure hose (2) at the gear (4). 5. Remove the pressure hose from the vehicle. Return Hose - Reservoir To Cooler RETURN HOSE - RESERVOIR TO COOLER 1. Drain and siphon the power steering system. 2. Disconnect the return hose at the reservoir. 3. Raise and support the vehicle. 4. Remove the return hose from the routing clamp at the fan shroud. 5. Disconnect the return hose at the cooler. 6. Remove the hose from the vehicle. Return Hose - Gear To Cooler Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hoses - I.F.S. > Page 12756 RETURN HOSE - GEAR TO COOLER 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reconnect the return hose (2) at the gear. Tighten the hose to 51 Nm (38 ft. lbs.). 4. Reattach the hose to the routing clip at the fan shroud. 5. Remove the support and lower the vehicle. 6. Refill the power steering system. Pressure Hose PRESSURE HOSE NOTE: Be sure to align the pressure hose so it does not contact the fan shroud or the frame rail. 1. Install the pressure hose to the vehicle. 2. Reconnect the pressure hose (2) at the gear (4). Tighten the hose to 32 Nm (23 ft. lbs.). 3. Reconnect the pressure hose at the pump. Tighten the hose to 36 Nm (27 ft. lbs.). 4. Remove the support and lower the vehicle. 5. Refill the power steering system. Return Hose - Reservoir To Cooler RETURN HOSE - RESERVOIR TO COOLER 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reattach the hose to the routing clip at the fan shroud. 4. Remove the support and lower the vehicle. 5. Reconnect the return hose at the reservoir. 6. Refill the power steering system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications Power Steering Pump: Specifications TORQUE Torque Specifications Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Description and Operation > Description Power Steering Pump: Description and Operation Description DESCRIPTION CAUTION: MOPAR(R) ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill. The pump is connected to the steering gear via the pressure hose and the return hose. The pump shaft has a pressed-on pulley that is belt driven by the crankshaft pulley. All vehicles are equipped with a power steering fluid cooler. NOTE: Power steering pumps are not interchangeable with pumps installed on other vehicles. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Description and Operation > Description > Page 12762 Power Steering Pump: Description and Operation Operation OPERATION Hydraulic pressure is provided for the power steering gear by the belt driven power steering pump (2). The power steering pumps are constant flow rate and displacement, vane-type pumps. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Testing and Inspection > Diagnosis And Testing - Pump Leakage Power Steering Pump: Testing and Inspection Diagnosis And Testing - Pump Leakage PUMP LEAKAGE The pump is serviced as an assembly and should not be disassembled. The plastic pump reservoir and the reservoir O-rings can be replaced. Check for leaks in the following areas: - Pump shaft seal behind the pulley - Pump to reservoir O-ring - Reservoir cap - Pressure and return lines - Flow control valve fitting Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Testing and Inspection > Diagnosis And Testing - Pump Leakage > Page 12765 Power Steering Pump: Testing and Inspection Diagnosis and Testing - Power Steering Pump and Hoses POWER STEERING PUMP AND HOSES NOTE: This information is designed to be used in conjunction with the diagnostic charts in the Steering information. CHECKING FOR WEAR OF POWER STEERING PUMP INTERNAL COMPONENTS 1. Place gear selector in PARK (or NEUTRAL) with wheels chalked. 2. With the engine idling, have a helper turn the steering wheel. 3. Using an electronic listening tool, determine if noise is coming from the pump. 4. Increase the engine speed and have a helper turn the steering wheel. Does the noise change with load? 5. Replace the power steering pump if excessive noise is present. CHECKING FOR POWER STEERING HOSES TOUCHING BODY OR FRAME OF VEHICLE Check hoses and hose tubes as following: - Inspect hoses and hose tubes for witness marks. If witness marks are present, adjust hose(s) to the proper position by loosening, repositioning and tightening attachments to the specified torque. Do not bend tubing to adjust. Replace the hose assembly if damaged. - Check fastener torque of hose mounting brackets and tube nuts. - Have a helper bump the steering gear off of the stops to induce pressure fluctuations which may move the hose. If hose contact is made, adjust hose(s) to the proper position by loosening, repositioning and tightening attachments to the specified torque. Do not bend tubing to adjust. Replace the hose assembly if damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Procedures Power Steering Pump: Procedures Power Steering System Bleeding POWER STEERING SYSTEM BLEEDING WARNING: The fluid level should be checked with engine off to prevent injury from moving components. CAUTION: Mopar(R) Power Steering Fluid + 4 or Mopar(R) ATF+4 Automatic Transmission Fluid is to be used in the power steering system. Both Fluids have the same material standard specifications (MS-9602). No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if another fluid is used. Do not overfill the system. CAUTION: If the air is not purged from the power steering system correctly, pump failure could result. NOTE: Be sure the vacuum tool used in the following procedure is clean and free of any fluids. 1. Check the fluid level. As measured on the side of the reservoir, the level should indicate between MAX and MIN when the fluid is at normal ambient temperature. Adjust the fluid level as necessary. 2. Tightly insert Power Steering Cap Adapter (4), Special Tool 9688, into the mouth of the reservoir (3). CAUTION: Failure to use a the vacuum pump reservoir (1) may allow power steering fluid to be sucked into the hand vacuum pump. 3. Attach Hand Vacuum Pump (2), Special Tool C-4207 or equivalent, with reservoir (1) attached, to the Power Steering Cap Adapter (4). CAUTION: Do not run the engine while vacuum is applied to the power steering system. Damage to the power steering pump can occur. NOTE: When performing the following step make sure the vacuum level is maintained during the entire time period. 4. Using Hand Vacuum Pump (2), apply 68-85 kPa (20-25 in. Hg) of vacuum to the system for a minimum of three minutes. 5. Slowly release the vacuum and remove the special tools. 6. Adjust the fluid level as necessary. Refer to STEP 1. 7. Repeat STEP 1 through STEP 6 until the fluid no longer drops when vacuum is applied. 8. Start the engine and cycle the steering wheel lock-to-lock three times. NOTE: Do not hold the steering wheel at the stops. 9. Stop the engine and check for leaks at all connections. 10. Check for any signs of air in the reservoir and check the fluid level. If air is present, repeat the procedure as necessary. Flushing Power Steering System Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Procedures > Page 12768 FLUSHING POWER STEERING SYSTEM Flushing is required when the power steering/hydraulic booster system fluid has become contaminated. Contaminated fluid in the steering/booster system can cause seal deterioration and affect steering gear/booster spool valve operation. NOTE: The engine should not be run so that all of the fluid is drained from the system. The pump should never be run without fluid. 1. Raise the front end of the vehicle off the ground until the wheels are free to turn. 2. Remove the return line from the pump. NOTE: If vehicle is equipped with a hydraulic booster remove both return lines from the pump. 3. Plug the return line port/ports at the pump. 4. Position the return line/lines into a large container to catch the fluid. 5. While an assistant is filling the pump reservoir start the engine. 6. With the engine running at idle turn the wheel back and forth. NOTE: Do not contact or hold the wheel against the steering stops. 7. Run a quart of fluid through the system then stop the engine and install the return line/lines. 8. Fill the system with fluid and perform Steering Pump Initial Operation. 9. Start the engine and run it for fifteen minutes then stop the engine. 10. Remove the return line/lines from the pump and plug the pump port/ports. 11. Pour fresh fluid into the reservoir and check the draining fluid for contamination. If the fluid is still contaminated, then flush the system again. 12. Install the return line/lines and perform Steering Pump Initial Operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Procedures > Page 12769 Power Steering Pump: Removal and Replacement Removal DIESEL ENGINE 1. Drain and siphon the power steering fluid from the reservoir. 2. Remove the serpentine belt. CAUTION: Do not remove the fitting on the pump that the high pressure hose screws into. The fitting may come loose unless it is backed up using another wrench. If the fitting does come loose, it must be retightened before continuing. (57 - 67 Nm, 40 - 50 lb.ft.). If this fitting comes out of the pump body, the internal spring and valve parts will fall out of the pump and they cannot be reinstalled properly. If this occurs the pump needs to be replaced with a new pump. 3. Disconnect the return hose. 4. Disconnect the pressure hose. 5. Access to remove the three bolts securing the pump to the cylinder head can be gained thru the pulley holes. 6. Loosen the pump bracket to the block. 7. Remove the 6 intake plenum bolts (1). 8. loosen the inner cooler tube clamp at the intake plenum and remove the intake plenum. 9. Loosen the inner cooler tube clamp at the radiator support side and remove the tube from the vehicle. 10. Remove the power steering pump (2) from the top of the engine compartment where the intake plenum was. Installation DIESEL ENGINE 1. Set the power steering pump (2) in place in the engine compartment from the top. 2. Install the inner cooler tube. 3. Tighten the inner cooler tube clamp at the radiator support side. 4. Install the 6 intake plenum bolts (2). 5. Tighten the inner cooler tube clamp at the intake plenum. 6. Install 3 pump mounting bolts through the pulley access holes. Tighten the bolts to 28 Nm (21 ft. lbs.). 7. Tighten the pump bracket to the block. 8. Reconnect the pressure line and return hose to the pump and reservoir. Tighten the pressure line to 37 Nm (27 ft. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Procedures > Page 12770 9. Install the serpentine drive belt. 10. Fill the power steering pump. Removal REMOVAL CAUTION: Do not reuse the old power steering pump pulley it is not intended for reuse. A new pulley must be installed if removed. 1. Remove the power steering pump assembly (1). 2. Remove the pulley (2) from the pump using (OTC(R) 7185) power steering pulley removal tool or equivalent (3). Installation INSTALLATION CAUTION: Do not reuse the old power steering pump pulley it is not intended for reuse. A new pulley must be installed if removed. 1. Replace the pulley (2) if it's bent, cracked, or loose. 2. Install the pulley (2) on the pump (1) using (OTC(R) 7771) power steering pulley installation tool or equivalent (3) making sure it is flush with the end of the shaft. Ensure the tool and pulley remain aligned with the pump shaft. 3. Install the power steering pump assembly. 4. Run engine until warm (5 min.) and note any belt chirp. If chirp exists, move pulley outward approximately 0.5 mm (0.020 in.). If noise increases, press on 1.0 mm (0.040 in.). Be careful that pulley does not contact mounting bolts. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations Steering Mounted Controls Communication Module: Locations Component ID: 212 Component : MODULE-STEERING CONTROL Connector: Name : MODULE-STEERING CONTROL C1 Color : WHITE # of pins : 6 Pin Description Circuit 1 GROUND Z909 20BK 2 RADIO CONTROL MUX X20 20GY/WT 3 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 4 S/C SWITCH NO. 1 SIGNAL V37 20VT 5 S/C SWITCH RETURN V937 20VT/BR 6 HORN SWITCH SENSE X3 20DG/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12775 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12776 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12777 Connector: Name : MODULE-STEERING CONTROL C2 Color : BLACK # of pins : 2 Qualifier : (PREMIUM) Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12778 2 RADIO CONTROL MUX X20 22GY/WT 2 RADIO CONTROL MUX X20 22GY/WT Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12779 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12780 Connector: Name : MODULE-STEERING CONTROL C3 Color : # of pins : 4 Pin Description Circuit 1 HORN SWITCH SENSE X3 20DG/VT 2 S/C SWITCH RETURN V937 22DB/DG 2 SENSOR GROUND K900 22DB/DG 3 S/C SWITCH NO. 1 SIGNAL V37 22VT 4 S/C SWITCH NO. 2 SIGNAL V38 22VT/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12781 Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12782 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12783 Connector: Name : MODULE-STEERING CONTROL C4 Color : YELLOW # of pins : 4 Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R61 20LG/VT 2 DRIVER SQUIB 2 LINE 2 R63 20LG/WT 3 DRIVER SQUIB 1 LINE 1 R43 20LG/BR 4 DRIVER SQUIB 1 LINE 2 R45 20LG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12784 Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12785 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12786 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12787 Steering Mounted Controls Communication Module: Diagrams Component ID: 212 Component : MODULE-STEERING CONTROL Connector: Name : MODULE-STEERING CONTROL C1 Color : WHITE # of pins : 6 Pin Description Circuit 1 GROUND Z909 20BK 2 RADIO CONTROL MUX X20 20GY/WT 3 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 4 S/C SWITCH NO. 1 SIGNAL V37 20VT 5 S/C SWITCH RETURN V937 20VT/BR 6 HORN SWITCH SENSE X3 20DG/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12788 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12789 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12790 Connector: Name : MODULE-STEERING CONTROL C2 Color : BLACK # of pins : 2 Qualifier : (PREMIUM) Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12791 2 RADIO CONTROL MUX X20 22GY/WT 2 RADIO CONTROL MUX X20 22GY/WT Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12792 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12793 Connector: Name : MODULE-STEERING CONTROL C3 Color : # of pins : 4 Pin Description Circuit 1 HORN SWITCH SENSE X3 20DG/VT 2 S/C SWITCH RETURN V937 22DB/DG 2 SENSOR GROUND K900 22DB/DG 3 S/C SWITCH NO. 1 SIGNAL V37 22VT 4 S/C SWITCH NO. 2 SIGNAL V38 22VT/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12794 Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12795 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12796 Connector: Name : MODULE-STEERING CONTROL C4 Color : YELLOW # of pins : 4 Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R61 20LG/VT 2 DRIVER SQUIB 2 LINE 2 R63 20LG/WT 3 DRIVER SQUIB 1 LINE 1 R43 20LG/BR 4 DRIVER SQUIB 1 LINE 2 R45 20LG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12797 Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12798 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12799 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Description Power Steering Pressure Switch: Description and Operation Description DESCRIPTION A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will only be used on HD vehicles with the 5.7L engines. There is no pressure switch used for the 3.7L, 4.7L, 5.9LDiesel engine or the 5.7L LD vehicle pump. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Description > Page 12805 Power Steering Pressure Switch: Description and Operation Operation OPERATION The switch is used on the 5.7L V-8 engines HD vehicles only. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will re-close and engine idle speed will return to its previous setting. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set Steering Angle Sensor: Customer Interest ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set NUMBER: 08-044-06 GROUP: Electrical DATE: October 07, 2006 SUBJECT: DTC C1240 - Steering Angle Sensor Over Travel Performance OVERVIEW: This bulletin involves the diagnosis and possible replacement of the Steering Angle Sensor. MODELS: 2007 (DR) Ram Truck NOTE: This bulletin applies to vehicle equipped with the Electronic Stability Program (sales code BNB) and built prior to October 03, 2006 (MDH 1003XX). SYMPTOM/CONDITION: The customer may experience an illumination on the instrument cluster of the "ABS" (Anti-Lock Brake System) and/or the "ESP / BAS" (Electronic Stability Program / Brake Assist System) Warning Lights. Investigation may reveal the presence of Diagnostic Trouble Code (DTC) C1240 Steering Angle Sensor Over Travel Performance (SAS). DIAGNOSIS: 1. Perform the diagnostic test procedure for DTC C1240. This diagnostic procedure can be found on TechCONNECT: select the SERVICE INFO tab > 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 340/445E5P AWAL > DIAGNOSIS and TESTING > C1240 - Steering Angle Sensor Over Travel Performance (SAS). 2. If the diagnostic test procedure for DTC C1240 determines that the Steering Angle Sensor is at fault, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Before starting this procedure, be certain that the front wheels are in the straight-ahead position. 1. Replace the steering column clockspring. Refer to TechCONNECT for detailed service procedures: select the SERVICE INFO tab > 8 - ELECTRICAL > RESTRAINTS > CLOCKSPRING > REMOVAL and INSTALLATION. 2. Clear offsets by initializing the ABS ECU using StarSCAN. 3. Perform the ABS VERIFICATION TEST. This test can be found in: 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 3401445E5P AWAL > STANDARD PROCEDURE > ABS VERIFICATION TEST. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set > Page 12814 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set Steering Angle Sensor: All Technical Service Bulletins ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set NUMBER: 08-044-06 GROUP: Electrical DATE: October 07, 2006 SUBJECT: DTC C1240 - Steering Angle Sensor Over Travel Performance OVERVIEW: This bulletin involves the diagnosis and possible replacement of the Steering Angle Sensor. MODELS: 2007 (DR) Ram Truck NOTE: This bulletin applies to vehicle equipped with the Electronic Stability Program (sales code BNB) and built prior to October 03, 2006 (MDH 1003XX). SYMPTOM/CONDITION: The customer may experience an illumination on the instrument cluster of the "ABS" (Anti-Lock Brake System) and/or the "ESP / BAS" (Electronic Stability Program / Brake Assist System) Warning Lights. Investigation may reveal the presence of Diagnostic Trouble Code (DTC) C1240 Steering Angle Sensor Over Travel Performance (SAS). DIAGNOSIS: 1. Perform the diagnostic test procedure for DTC C1240. This diagnostic procedure can be found on TechCONNECT: select the SERVICE INFO tab > 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 340/445E5P AWAL > DIAGNOSIS and TESTING > C1240 - Steering Angle Sensor Over Travel Performance (SAS). 2. If the diagnostic test procedure for DTC C1240 determines that the Steering Angle Sensor is at fault, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Before starting this procedure, be certain that the front wheels are in the straight-ahead position. 1. Replace the steering column clockspring. Refer to TechCONNECT for detailed service procedures: select the SERVICE INFO tab > 8 - ELECTRICAL > RESTRAINTS > CLOCKSPRING > REMOVAL and INSTALLATION. 2. Clear offsets by initializing the ABS ECU using StarSCAN. 3. Perform the ABS VERIFICATION TEST. This test can be found in: 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 3401445E5P AWAL > STANDARD PROCEDURE > ABS VERIFICATION TEST. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set > Page 12820 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set Steering Angle Sensor: Customer Interest ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set NUMBER: 08-044-06 GROUP: Electrical DATE: October 07, 2006 SUBJECT: DTC C1240 - Steering Angle Sensor Over Travel Performance OVERVIEW: This bulletin involves the diagnosis and possible replacement of the Steering Angle Sensor. MODELS: 2007 (DR) Ram Truck NOTE: This bulletin applies to vehicle equipped with the Electronic Stability Program (sales code BNB) and built prior to October 03, 2006 (MDH 1003XX). SYMPTOM/CONDITION: The customer may experience an illumination on the instrument cluster of the "ABS" (Anti-Lock Brake System) and/or the "ESP / BAS" (Electronic Stability Program / Brake Assist System) Warning Lights. Investigation may reveal the presence of Diagnostic Trouble Code (DTC) C1240 Steering Angle Sensor Over Travel Performance (SAS). DIAGNOSIS: 1. Perform the diagnostic test procedure for DTC C1240. This diagnostic procedure can be found on TechCONNECT: select the SERVICE INFO tab > 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 340/445E5P AWAL > DIAGNOSIS and TESTING > C1240 - Steering Angle Sensor Over Travel Performance (SAS). 2. If the diagnostic test procedure for DTC C1240 determines that the Steering Angle Sensor is at fault, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Before starting this procedure, be certain that the front wheels are in the straight-ahead position. 1. Replace the steering column clockspring. Refer to TechCONNECT for detailed service procedures: select the SERVICE INFO tab > 8 - ELECTRICAL > RESTRAINTS > CLOCKSPRING > REMOVAL and INSTALLATION. 2. Clear offsets by initializing the ABS ECU using StarSCAN. 3. Perform the ABS VERIFICATION TEST. This test can be found in: 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 3401445E5P AWAL > STANDARD PROCEDURE > ABS VERIFICATION TEST. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set > Page 12829 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set Steering Angle Sensor: All Technical Service Bulletins ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set NUMBER: 08-044-06 GROUP: Electrical DATE: October 07, 2006 SUBJECT: DTC C1240 - Steering Angle Sensor Over Travel Performance OVERVIEW: This bulletin involves the diagnosis and possible replacement of the Steering Angle Sensor. MODELS: 2007 (DR) Ram Truck NOTE: This bulletin applies to vehicle equipped with the Electronic Stability Program (sales code BNB) and built prior to October 03, 2006 (MDH 1003XX). SYMPTOM/CONDITION: The customer may experience an illumination on the instrument cluster of the "ABS" (Anti-Lock Brake System) and/or the "ESP / BAS" (Electronic Stability Program / Brake Assist System) Warning Lights. Investigation may reveal the presence of Diagnostic Trouble Code (DTC) C1240 Steering Angle Sensor Over Travel Performance (SAS). DIAGNOSIS: 1. Perform the diagnostic test procedure for DTC C1240. This diagnostic procedure can be found on TechCONNECT: select the SERVICE INFO tab > 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 340/445E5P AWAL > DIAGNOSIS and TESTING > C1240 - Steering Angle Sensor Over Travel Performance (SAS). 2. If the diagnostic test procedure for DTC C1240 determines that the Steering Angle Sensor is at fault, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Before starting this procedure, be certain that the front wheels are in the straight-ahead position. 1. Replace the steering column clockspring. Refer to TechCONNECT for detailed service procedures: select the SERVICE INFO tab > 8 - ELECTRICAL > RESTRAINTS > CLOCKSPRING > REMOVAL and INSTALLATION. 2. Clear offsets by initializing the ABS ECU using StarSCAN. 3. Perform the ABS VERIFICATION TEST. This test can be found in: 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 3401445E5P AWAL > STANDARD PROCEDURE > ABS VERIFICATION TEST. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set > Page 12835 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation Air Bag(s) Arming and Disarming: Technical Service Bulletins Air Bag System - Passenger Air Bag Deactivation NUMBER: 08-001-07 REV. B GROUP: Electrical DATE: May 16, 2007 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED. THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION. DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION. SUBJECT: Passenger Air Bag Deactivation MODELS: 2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 0300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakoka 2006 - 2007 (DR) Ram Truck 2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 12841 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet. NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States. PARTS REQUIRED: POLICY: Information Only Disclaimer: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 12842 This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Steering Column Opening Cover Steering Column Cover: Service and Repair Steering Column Opening Cover Removal REMOVAL 1. Remove the park brake release handle. 2. Remove the two screws that secure the bottom of the steering column opening cover (3) to the instrument panel. 3. Using a trim stick C-4755 or equivalent, release the two retainer clips that secure the top of the steering column opening cover (2) to the instrument panel and remove the cover. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Steering Column Opening Cover > Page 12847 4. Remove the screws and remove the knee blocker. Installation INSTALLATION 1. Install the knee blocker (2) and install the screws (1). 2. Position the steering column opening cover (2) to the instrument panel and fully engage the two upper retainer clips to the instrument panel. 3. Install the two screws that secure the steering column opening cover to the instrument panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Steering Column Opening Cover > Page 12848 4. Install the park brake release handle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Steering Column Opening Cover > Page 12849 Steering Column Cover: Service and Repair Steering Column Opening Support Bracket Removal REMOVAL 1. Remove the steering column opening cover from the instrument panel (1). 2. Remove the hood release handle from the steering column opening support bracket (2). 3. Disengage the retaining tabs that secure the data link connector (3) to the steering column opening support bracket and remove the data link connector from the bracket. 4. Remove the two screws (4) that secure the steering column opening support bracket (3) to the instrument panel (2). 5. Slide the steering column opening support bracket upward to disengage the two locating tabs (1) and remove the bracket. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Steering Column Opening Cover > Page 12850 1. Position the steering column opening bracket (3) onto the instrument panel (2) and engage to the two locating tabs (1). 2. Install the two screws (4) that secure the steering column opening bracket to the instrument panel. Tighten the screws to 2.2 Nm (20 in. lbs.). 3. Position the data link connector (3) into the opening in the steering column opening bracket (2) and fully engage the retaining tabs that secure the connector to the bracket. 4. Install the hood release handle. 5. Install the steering column opening cover onto the instrument panel (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Lock: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Steering Column Lock: Customer Interest Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Lock: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12859 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Lock: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12860 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Lock: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12861 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > Customer Interest for Steering Column Lock: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12862 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Lock: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Steering Column Lock: All Technical Service Bulletins Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Lock: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12868 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Lock: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12869 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Lock: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12870 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Lock: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 12871 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Handle > Component Information > Service and Repair > Removal Tilt Wheel Handle: Service and Repair Removal REMOVAL 1. Remove the screw (1) securing the tilt lever knob (2). 2. Remove the steering column opening cover. 3. Remove the lower shroud. NOTE: Use special care not to pry on the clockspring electrical connector when removing or installing the mounting screw located next to the clockspring. 4. Remove the two mounting screws (1) from the tilt lever knob release bracket (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Handle > Component Information > Service and Repair > Removal > Page 12876 5. Unseat the rod (2) from the release lever assembly (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Handle > Component Information > Service and Repair > Removal > Page 12877 Tilt Wheel Handle: Service and Repair Installation INSTALLATION 1. Route the rod (2) into the tilt lever release knob bracket (1). 2. Install the tilt lever release knob bracket (3) to the column and install the two new mounting screws (1). Tighten the two screws to 4.5 Nm (40 in. lbs.). 3. Install the lower shroud. 4. Install the steering column opening cover. 5. Install the tilt lever knob (2) and screw (1). Tighten the screw to 4.5 Nm (40 in. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > Recalls: > H46 > Jun > 09 > Recall - Steering Linkage Defects Technical Service Bulletin # H46 Date: 090609 Recall - Steering Linkage Defects Revised May 2009 Dealer Service Instructions for: Safety Recall H46 - Mopar Steering Linkage NOTE: The service procedure for this recall has been revised and additional labor operations have been added. All previous copies of Safety Recall H46 should be discarded from your files. Models 2003-2004 (DR) Dodge Truck 4x4 (2500/3500 series) 2005 (DH) Dodge Truck 4x4 (2500/3500 series) 2006-2009 (DH) Dodge Truck 4x4 (2500/3500 series or 1500 Mega Cab) 2006-2009 (D1) Dodge Truck 4x4 (3500 series) 2007-2009 (DC) Dodge Truck (3500 series cab chassis) IMPORTANT: This recall only applies to vehicles that had certain Mopar service parts steering components installed. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject During a prior service appointment, a Mopar service parts steering linkage was installed on about 19,400 of the above vehicles. The drag link inner joint may fracture under certain driving conditions. This could result in a loss of steering control and cause a crash without warning. Also, the steering damper bracket at the tie rod tube may loosen. This could allow the bracket to slide on the tube and may cause increased vehicle turning radius. Repair The steering linkage must be inspected and some steering linkage components may need to be replaced. NOTE: The initial steering linkage inspection process can be done by write up personnel in the write up area (see Step 1 of the service procedure). Vehicles found with original style steering linkage can be immediately returned to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > Recalls: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12886 Parts Information Special Tools The special tools may be required to perform this repair: Completion Reporting and Reimbursement Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > Recalls: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12887 Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. FOR VEHICLES INSPECTED IN THE WRITE UP AREA: Enter "INSPECT" in the part number section of your claim with a quantity of one (1). Enter $5.00 WITH NO MARK-UP for reimbursement of steering linkage inspection performed in the write up area. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > Recalls: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12888 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure NOTE: The initial steering linkage inspection process (Step 1 of the service procedure) can be done by write up personnel in the write up area. Vehicles found with the steering linkage shown in Figure 1 can be immediately returned to the customer. See the "Completion Reporting and Reimbursement" section of this recall for special claims processing information. 1. Look under the front of the vehicle and inspect the steering linkage at the steering damper mounting point: > If the steering damper mounts to the tie rod tube as shown in Figure 1, the steering linkage is good. Return the vehicle to the customer. No further action is required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > Recalls: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12889 > If the steering damper mounts to the tie rod tube as shown in Figure 2, the vehicle will require further inspection and/or repair by a technician. The vehicle should be assigned to a technician and the technician should continue with Step 2 of this procedure. 2. Lift the vehicle on a hoist and inspect the steering linkage drag link for a white part number tag (Figure 3): > If the steering linkage drag link does not have a white part number tag, continue with Step 3 of this procedure. ^ If the steering linkage drag link has a white part number tag: > For 2009 model year trucks, continue with Step 9 of this procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > Recalls: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12890 > For 2003 through 2008 model year trucks, continue with Step 5 of this procedure. 3. Inspect the steering damper bracket to tie rod tube mounting u-bolt nuts by putting a 13 mm box-end wrench onto the nut (Figure 4): > If a 13 mm wrench fits the steering damper bracket mounting u-bolt nuts, the bracket and fasteners must be replaced. Continue with Step 4 of this procedure. > If a 13 mm wrench does not fit the steering damper bracket mounting u-bolt nuts, the bracket does not require replacement. Continue with Step 5 of this procedure. 4. Replace the steering damper bracket and fasteners using the following procedure: a. Remove and save the steering damper-to-damper bracket mounting nut (Figure 5). b. Disconnect the steering damper eyelet from the steering damper bracket. c. Remove and discard the four steering damper bracket nuts, two u-bolts and the steering damper bracket (Figure 5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > Recalls: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12891 d. Place the new steering damper carriage bolt through the square hole in the new steering damper bracket. e. Place the new steering damper bracket assembly onto the tie rod tube at the flat spot area on the tube and install the new u-bolts and nuts. Lightly snug the nuts to hold the steering damper bracket in position. f. Center the new steering damper bracket on the flattened area of the tie rod tube. g. Evenly tighten the four steering damper bracket u-bolt nuts to 25 ft. lbs. (34 N.m). Then tighten the four u-bolt nuts to 45 ft. lbs. (61 N.m). h. Connect the steering damper to the steering damper carriage bolt. i. Install the steering damper-to-damper bracket mounting nut and tighten to 75 ft. lbs. (100 N.m). j. Continue with Step 5 of this procedure. 5. For 2009 model year trucks, continue with Step 6 of this procedure. For 2003 through 2008 model year trucks, inspect the pitman arm part number (Figure 6): > If the part number cast into the bottom side of the pitman arm is 68039930AA the pitman arm does not require replacement. > Steering linkage with a white part number tag, continue with Step 9 of this procedure. > Linkage without a white part number tag, replace the inner drag link joint. Continue with Step 6 of this procedure. > If the part number cast into the bottom side of the pitman arm is 52106836AB, or is not legible: > Steering linkage without a white part number tag, replace the inner drag link joint and pitman arm. Continue with Step 7 of this procedure. > Steering linkage with a white part number tag, replace the pitman arm. Continue with Step 8 of this procedure. 6. Replace the inner drag link joint using the following procedure: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > Recalls: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12892 a. Loosen both drag link adjuster sleeve clamp nuts (Figure 7). b. Remove and discard the inner drag link joint to pitman arm nut (Figure 7). c. Use Special Tool C-4150A to separate the steering inner drag link joint from the pitman arm (Figure 8). d. While counting the number of turns, unscrew the steering inner drag link joint from the drag link adjuster sleeve (right handed threads) and discard the drag link inner joint. CAUTION: Do not allow the drag link adjuster sleeve to turn while unscrewing the inner drag link joint. e. Screw in the new inner drag link joint into the drag link adjuster sleeve the same number of turns counted in step 6d. of this procedure. f. Connect the steering inner drag link joint to the pitman arm. g. Install the new steering inner drag link joint nut and tighten the nut to 100 ft. lbs. (135 N.m). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > Recalls: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12893 h. With the wheels in the straight ahead position, make sure that both inner and outer steering drag link joint caps are centered over the joint ball stud (Figure 9). CAUTION: Failure to center the drag link inner and outer joint caps over the joint ball studs before tightening the drag link adjuster sleeve clamps could cause joint failure. i. With the adjuster sleeve clamps rotated 45 degrees forward, tighten both drag link adjuster sleeve clamp nuts to 45 ft. lbs. (61 N.m). CAUTION: The drag link adjuster sleeve clamp tabs must be pointing approximately 45 degrees forward before tightening (as shown in Figure 10). Do not allow the adjuster sleeve clamp tabs to hang straight down. j. Lower the vehicle from the hoist. k. Drive the vehicle to verify that the steering wheel is straight. > If the steering wheel is turned to the left, shorten the drag link at the adjuster sleeve located on the drag link. > If the steering wheel is turned to the right, lengthen the drag link at the adjuster sleeve located on the drag link. l. Repeat Step 6k. until steering wheel is straight. m. Continue with Step 9 of this procedure. 7. Replace the inner drag link joint and pitman arm using the following procedure: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > Recalls: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12894 a. Loosen both drag link adjuster sleeve clamp nuts (Figure 7). b. Remove and save the pitman arm retaining nut located on the steering gear output shaft. c. Install pitman arm puller (Special Tool 9615) onto the steering gear output shaft (Figure 11). CAUTION: Failure to use the correct pitman arm puller could cause damage to the steering gear. d. Tighten the pitman arm puller forcing screw until the pitman arm separates from the steering gear output shaft (Figure 11). e. While counting the number of turns, unscrew the steering inner drag link joint (with pitman arm still attached) from the drag link adjuster sleeve (right handed threads) and discard the pitman arm and inner drag link joint. CAUTION: Do not allow the drag link adjuster sleeve to turn while unscrewing the inner drag link joint. f. Screw in the new steering inner drag link joint into the drag link adjuster sleeve the same number of turns counted in step 7e. of this procedure. g. Install the new pitman arm and retaining nut onto the steering gear output shaft. Tighten the pitman arm nut to 225 ft. lbs. (300 N.m). h. Connect the steering inner drag link joint to the pitman arm. i. Install the new steering inner drag link joint nut and tighten the nut to 100 ft. lbs. (135 N.m). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > Recalls: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12895 j. With the wheels in the straight ahead position, make sure that both inner and outer steering drag link joint caps are centered over the joint ball stud (Figure 12). CAUTION: Failure to center the drag link inner and outer joint caps over the joint ball studs before tightening the drag link adjuster sleeve clamps could cause joint failure. k. With the adjuster sleeve clamps rotated 45 degrees forward, tighten the drag link adjuster sleeve clamp nuts to 45 ft. lbs. (61 N.m).lbs. CAUTION: The drag link adjuster sleeve clamp tabs must be pointing approximately 45 degrees forward before tightening (as shown in Figure 10). Do not allow the adjuster sleeve clamp tabs to hang straight down. l. Lower the vehicle from the hoist. m. Drive the vehicle to verify that the steering wheel is straight. > If the steering wheel is turned to the left, shorten the drag link at the adjuster sleeve located on the drag link. > If the steering wheel is turned to the right, lengthen the drag link at the adjuster sleeve located on the drag link. n. Repeat Step 7m. until steering wheel is straight. o. Continue with Step 9 of this procedure. 8. Replace the pitman arm using the following procedure: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > Recalls: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12896 a. Remove and discard the inner drag link joint nut (Figure 13). b. Use Special Tool C-4150A to separate the steering inner drag link joint from the pitman arm (Figure 14). CAUTION: Use extreme care not to tear, nick or damage the inner drag link joint rubber boot. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > Recalls: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12897 d. Install pitman arm puller (Special Tool 9615) onto the steering gear output shaft (Figure 15). CAUTION: Failure to use the correct pitman arm puller could cause damage to the steering gear. e. Tighten the pitman arm puller forcing screw until the pitman arm separates from the steering gear output shaft (Figure 15). f. Install the new pitman arm. g. Install the pitman arm retaining nut onto the steering gear output shaft. Tighten the pitman arm nut to 225 ft. lbs. (300 N.m). h. Connect the steering inner drag link joint to the pitman arm. i. Install the new steering inner drag link joint nut and tighten the nut to 100 ft. lbs. (135 N.m). j. Lower the vehicle from the hoist. k. Drive the vehicle to verify that the steering wheel is straight. > If the steering wheel is turned to the left, shorten the drag link at the adjuster sleeve located on the drag link. ^ If the steering wheel is turned to the right, lengthen the drag link at the adjuster sleeve located on the drag link. l. Repeat Step 8k. until steering wheel is straight. m. Continue with Step 9 of this procedure. 9. Verify the lower surface of the left outer tie rod socket is parallel to the upper surface of the left knuckle attaching arm using the following procedure: a. Loosen the tie rod tube adjuster sleeve clamps. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > Recalls: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12898 b. Rotate the left tie rod until the bottom of the tie rod socket is parallel to the top of the left steering knuckle arm (Figure 16). c. Tighten the tie rod adjuster sleeve clamp nuts to 45 ft.lbs. (61 N.m). CAUTION: Failure to align the left tie rod end parallel to the steering knuckle could cause tie rod end damage. d. Return the vehicle to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > Recalls: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12899 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > Customer Interest: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads Steering Damper: Customer Interest Steering - Front End Shimmy On Rough Roads NUMBER: 22-005-06 GROUP: Tire & Wheels DATE: October 07, 2006 SUBJECT: Front End Shimmy On 4x4 Vehicles When Traveling Over Rough Surfaces In The Road OVERVIEW: This bulletin involves verifying the condition of the vehicle front suspension and steering components, and adjusting the front tire pressure. MODELS: 2003 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to four wheel drive (4x4) 2500 and 3500 model vehicles. SYMPTOM/CONDITION: The customer may experience a self sustaining vibration (shimmy) felt in the front end of the vehicle after striking a bump or pothole. DIAGNOSIS: If the customer experiences the above condition perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on an alignment rack (drive-on lift). 2. Verify the road tires are correctly sized and the tire tread is not excessively worn. Replace any worn tire before proceeding. Any new or old replacement tire should be equal to the original tires that came with the vehicle when it was new. Tire wear is not covered by the vehicle warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > Customer Interest: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads > Page 12905 3. Set the tire pressure for the FRONT TIRES to the following specification, regardless of the load being carried by the vehicle. 4. Set the tire pressure for the REAR TIRES as recommended for the vehicle configuration and load that is being carried at the time. 5. Verify that the steering damper is operating correctly. a. Unbolt the end of the damper at the axle end. b. Cycle the damper rod by hand. c. There should be resistance to motion in both directions of the damper rod. d. Replace the damper if no resistance is present. 6. Verify both outer tie rod ends dust covers are not worn. a. Attempt to rotate the dust cover by hand. b. If the dust cover on an outer tie rod end can be rotated, or is free and loose, then replace the tie rod (regardless of joint wear). 7. Inspect each outer tie rod end for internal wear. a. Maximum allowed wear (joint travel) for a tie rod end is 1.15 mm (0.045 in.). b. Install a dial indicator to the tie rod end (in-line with the vertical stud of the tie rod end). c. With a pry bar placed between the steering linkage and the axle tube, pry upwards while measuring the amount of joint travel (wear). d. Measure the amount of wear in the other outer tie rod end joint. e. If wear (joint travel) in either outer tie rod end is greater than 1.15 mm (0.045 in.), then replace the worn tie rod end. 8. Verify the torque on each outer tie rod end stud nut. The nut should be tightened to 122 Nm (90 ft. lbs.). 9. Make sure any worn outer tie rod ends have been replaced before proceeding further. 10. Verify all other steering linkage connections are tightened to their torque specifications. 11. Grease both outer tie rod ends (even if the outer tie rod is new). Apply sufficient grease to each tie rod end until grease is seen purging from the joint at the dust seal. 12. Align the vehicle front end. Adjust to specifications. 13. Road test the vehicle and verify the shimmy condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > Customer Interest: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads > Page 12906 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects Technical Service Bulletin # H46 Date: 090609 Recall - Steering Linkage Defects Revised May 2009 Dealer Service Instructions for: Safety Recall H46 - Mopar Steering Linkage NOTE: The service procedure for this recall has been revised and additional labor operations have been added. All previous copies of Safety Recall H46 should be discarded from your files. Models 2003-2004 (DR) Dodge Truck 4x4 (2500/3500 series) 2005 (DH) Dodge Truck 4x4 (2500/3500 series) 2006-2009 (DH) Dodge Truck 4x4 (2500/3500 series or 1500 Mega Cab) 2006-2009 (D1) Dodge Truck 4x4 (3500 series) 2007-2009 (DC) Dodge Truck (3500 series cab chassis) IMPORTANT: This recall only applies to vehicles that had certain Mopar service parts steering components installed. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject During a prior service appointment, a Mopar service parts steering linkage was installed on about 19,400 of the above vehicles. The drag link inner joint may fracture under certain driving conditions. This could result in a loss of steering control and cause a crash without warning. Also, the steering damper bracket at the tie rod tube may loosen. This could allow the bracket to slide on the tube and may cause increased vehicle turning radius. Repair The steering linkage must be inspected and some steering linkage components may need to be replaced. NOTE: The initial steering linkage inspection process can be done by write up personnel in the write up area (see Step 1 of the service procedure). Vehicles found with original style steering linkage can be immediately returned to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12912 Parts Information Special Tools The special tools may be required to perform this repair: Completion Reporting and Reimbursement Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12913 Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. FOR VEHICLES INSPECTED IN THE WRITE UP AREA: Enter "INSPECT" in the part number section of your claim with a quantity of one (1). Enter $5.00 WITH NO MARK-UP for reimbursement of steering linkage inspection performed in the write up area. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12914 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure NOTE: The initial steering linkage inspection process (Step 1 of the service procedure) can be done by write up personnel in the write up area. Vehicles found with the steering linkage shown in Figure 1 can be immediately returned to the customer. See the "Completion Reporting and Reimbursement" section of this recall for special claims processing information. 1. Look under the front of the vehicle and inspect the steering linkage at the steering damper mounting point: > If the steering damper mounts to the tie rod tube as shown in Figure 1, the steering linkage is good. Return the vehicle to the customer. No further action is required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12915 > If the steering damper mounts to the tie rod tube as shown in Figure 2, the vehicle will require further inspection and/or repair by a technician. The vehicle should be assigned to a technician and the technician should continue with Step 2 of this procedure. 2. Lift the vehicle on a hoist and inspect the steering linkage drag link for a white part number tag (Figure 3): > If the steering linkage drag link does not have a white part number tag, continue with Step 3 of this procedure. ^ If the steering linkage drag link has a white part number tag: > For 2009 model year trucks, continue with Step 9 of this procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12916 > For 2003 through 2008 model year trucks, continue with Step 5 of this procedure. 3. Inspect the steering damper bracket to tie rod tube mounting u-bolt nuts by putting a 13 mm box-end wrench onto the nut (Figure 4): > If a 13 mm wrench fits the steering damper bracket mounting u-bolt nuts, the bracket and fasteners must be replaced. Continue with Step 4 of this procedure. > If a 13 mm wrench does not fit the steering damper bracket mounting u-bolt nuts, the bracket does not require replacement. Continue with Step 5 of this procedure. 4. Replace the steering damper bracket and fasteners using the following procedure: a. Remove and save the steering damper-to-damper bracket mounting nut (Figure 5). b. Disconnect the steering damper eyelet from the steering damper bracket. c. Remove and discard the four steering damper bracket nuts, two u-bolts and the steering damper bracket (Figure 5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12917 d. Place the new steering damper carriage bolt through the square hole in the new steering damper bracket. e. Place the new steering damper bracket assembly onto the tie rod tube at the flat spot area on the tube and install the new u-bolts and nuts. Lightly snug the nuts to hold the steering damper bracket in position. f. Center the new steering damper bracket on the flattened area of the tie rod tube. g. Evenly tighten the four steering damper bracket u-bolt nuts to 25 ft. lbs. (34 N.m). Then tighten the four u-bolt nuts to 45 ft. lbs. (61 N.m). h. Connect the steering damper to the steering damper carriage bolt. i. Install the steering damper-to-damper bracket mounting nut and tighten to 75 ft. lbs. (100 N.m). j. Continue with Step 5 of this procedure. 5. For 2009 model year trucks, continue with Step 6 of this procedure. For 2003 through 2008 model year trucks, inspect the pitman arm part number (Figure 6): > If the part number cast into the bottom side of the pitman arm is 68039930AA the pitman arm does not require replacement. > Steering linkage with a white part number tag, continue with Step 9 of this procedure. > Linkage without a white part number tag, replace the inner drag link joint. Continue with Step 6 of this procedure. > If the part number cast into the bottom side of the pitman arm is 52106836AB, or is not legible: > Steering linkage without a white part number tag, replace the inner drag link joint and pitman arm. Continue with Step 7 of this procedure. > Steering linkage with a white part number tag, replace the pitman arm. Continue with Step 8 of this procedure. 6. Replace the inner drag link joint using the following procedure: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12918 a. Loosen both drag link adjuster sleeve clamp nuts (Figure 7). b. Remove and discard the inner drag link joint to pitman arm nut (Figure 7). c. Use Special Tool C-4150A to separate the steering inner drag link joint from the pitman arm (Figure 8). d. While counting the number of turns, unscrew the steering inner drag link joint from the drag link adjuster sleeve (right handed threads) and discard the drag link inner joint. CAUTION: Do not allow the drag link adjuster sleeve to turn while unscrewing the inner drag link joint. e. Screw in the new inner drag link joint into the drag link adjuster sleeve the same number of turns counted in step 6d. of this procedure. f. Connect the steering inner drag link joint to the pitman arm. g. Install the new steering inner drag link joint nut and tighten the nut to 100 ft. lbs. (135 N.m). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12919 h. With the wheels in the straight ahead position, make sure that both inner and outer steering drag link joint caps are centered over the joint ball stud (Figure 9). CAUTION: Failure to center the drag link inner and outer joint caps over the joint ball studs before tightening the drag link adjuster sleeve clamps could cause joint failure. i. With the adjuster sleeve clamps rotated 45 degrees forward, tighten both drag link adjuster sleeve clamp nuts to 45 ft. lbs. (61 N.m). CAUTION: The drag link adjuster sleeve clamp tabs must be pointing approximately 45 degrees forward before tightening (as shown in Figure 10). Do not allow the adjuster sleeve clamp tabs to hang straight down. j. Lower the vehicle from the hoist. k. Drive the vehicle to verify that the steering wheel is straight. > If the steering wheel is turned to the left, shorten the drag link at the adjuster sleeve located on the drag link. > If the steering wheel is turned to the right, lengthen the drag link at the adjuster sleeve located on the drag link. l. Repeat Step 6k. until steering wheel is straight. m. Continue with Step 9 of this procedure. 7. Replace the inner drag link joint and pitman arm using the following procedure: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12920 a. Loosen both drag link adjuster sleeve clamp nuts (Figure 7). b. Remove and save the pitman arm retaining nut located on the steering gear output shaft. c. Install pitman arm puller (Special Tool 9615) onto the steering gear output shaft (Figure 11). CAUTION: Failure to use the correct pitman arm puller could cause damage to the steering gear. d. Tighten the pitman arm puller forcing screw until the pitman arm separates from the steering gear output shaft (Figure 11). e. While counting the number of turns, unscrew the steering inner drag link joint (with pitman arm still attached) from the drag link adjuster sleeve (right handed threads) and discard the pitman arm and inner drag link joint. CAUTION: Do not allow the drag link adjuster sleeve to turn while unscrewing the inner drag link joint. f. Screw in the new steering inner drag link joint into the drag link adjuster sleeve the same number of turns counted in step 7e. of this procedure. g. Install the new pitman arm and retaining nut onto the steering gear output shaft. Tighten the pitman arm nut to 225 ft. lbs. (300 N.m). h. Connect the steering inner drag link joint to the pitman arm. i. Install the new steering inner drag link joint nut and tighten the nut to 100 ft. lbs. (135 N.m). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12921 j. With the wheels in the straight ahead position, make sure that both inner and outer steering drag link joint caps are centered over the joint ball stud (Figure 12). CAUTION: Failure to center the drag link inner and outer joint caps over the joint ball studs before tightening the drag link adjuster sleeve clamps could cause joint failure. k. With the adjuster sleeve clamps rotated 45 degrees forward, tighten the drag link adjuster sleeve clamp nuts to 45 ft. lbs. (61 N.m).lbs. CAUTION: The drag link adjuster sleeve clamp tabs must be pointing approximately 45 degrees forward before tightening (as shown in Figure 10). Do not allow the adjuster sleeve clamp tabs to hang straight down. l. Lower the vehicle from the hoist. m. Drive the vehicle to verify that the steering wheel is straight. > If the steering wheel is turned to the left, shorten the drag link at the adjuster sleeve located on the drag link. > If the steering wheel is turned to the right, lengthen the drag link at the adjuster sleeve located on the drag link. n. Repeat Step 7m. until steering wheel is straight. o. Continue with Step 9 of this procedure. 8. Replace the pitman arm using the following procedure: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12922 a. Remove and discard the inner drag link joint nut (Figure 13). b. Use Special Tool C-4150A to separate the steering inner drag link joint from the pitman arm (Figure 14). CAUTION: Use extreme care not to tear, nick or damage the inner drag link joint rubber boot. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12923 d. Install pitman arm puller (Special Tool 9615) onto the steering gear output shaft (Figure 15). CAUTION: Failure to use the correct pitman arm puller could cause damage to the steering gear. e. Tighten the pitman arm puller forcing screw until the pitman arm separates from the steering gear output shaft (Figure 15). f. Install the new pitman arm. g. Install the pitman arm retaining nut onto the steering gear output shaft. Tighten the pitman arm nut to 225 ft. lbs. (300 N.m). h. Connect the steering inner drag link joint to the pitman arm. i. Install the new steering inner drag link joint nut and tighten the nut to 100 ft. lbs. (135 N.m). j. Lower the vehicle from the hoist. k. Drive the vehicle to verify that the steering wheel is straight. > If the steering wheel is turned to the left, shorten the drag link at the adjuster sleeve located on the drag link. ^ If the steering wheel is turned to the right, lengthen the drag link at the adjuster sleeve located on the drag link. l. Repeat Step 8k. until steering wheel is straight. m. Continue with Step 9 of this procedure. 9. Verify the lower surface of the left outer tie rod socket is parallel to the upper surface of the left knuckle attaching arm using the following procedure: a. Loosen the tie rod tube adjuster sleeve clamps. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12924 b. Rotate the left tie rod until the bottom of the tie rod socket is parallel to the top of the left steering knuckle arm (Figure 16). c. Tighten the tie rod adjuster sleeve clamp nuts to 45 ft.lbs. (61 N.m). CAUTION: Failure to align the left tie rod end parallel to the steering knuckle could cause tie rod end damage. d. Return the vehicle to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12925 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Damper: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads Steering Damper: All Technical Service Bulletins Steering - Front End Shimmy On Rough Roads NUMBER: 22-005-06 GROUP: Tire & Wheels DATE: October 07, 2006 SUBJECT: Front End Shimmy On 4x4 Vehicles When Traveling Over Rough Surfaces In The Road OVERVIEW: This bulletin involves verifying the condition of the vehicle front suspension and steering components, and adjusting the front tire pressure. MODELS: 2003 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to four wheel drive (4x4) 2500 and 3500 model vehicles. SYMPTOM/CONDITION: The customer may experience a self sustaining vibration (shimmy) felt in the front end of the vehicle after striking a bump or pothole. DIAGNOSIS: If the customer experiences the above condition perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on an alignment rack (drive-on lift). 2. Verify the road tires are correctly sized and the tire tread is not excessively worn. Replace any worn tire before proceeding. Any new or old replacement tire should be equal to the original tires that came with the vehicle when it was new. Tire wear is not covered by the vehicle warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Damper: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads > Page 12930 3. Set the tire pressure for the FRONT TIRES to the following specification, regardless of the load being carried by the vehicle. 4. Set the tire pressure for the REAR TIRES as recommended for the vehicle configuration and load that is being carried at the time. 5. Verify that the steering damper is operating correctly. a. Unbolt the end of the damper at the axle end. b. Cycle the damper rod by hand. c. There should be resistance to motion in both directions of the damper rod. d. Replace the damper if no resistance is present. 6. Verify both outer tie rod ends dust covers are not worn. a. Attempt to rotate the dust cover by hand. b. If the dust cover on an outer tie rod end can be rotated, or is free and loose, then replace the tie rod (regardless of joint wear). 7. Inspect each outer tie rod end for internal wear. a. Maximum allowed wear (joint travel) for a tie rod end is 1.15 mm (0.045 in.). b. Install a dial indicator to the tie rod end (in-line with the vertical stud of the tie rod end). c. With a pry bar placed between the steering linkage and the axle tube, pry upwards while measuring the amount of joint travel (wear). d. Measure the amount of wear in the other outer tie rod end joint. e. If wear (joint travel) in either outer tie rod end is greater than 1.15 mm (0.045 in.), then replace the worn tie rod end. 8. Verify the torque on each outer tie rod end stud nut. The nut should be tightened to 122 Nm (90 ft. lbs.). 9. Make sure any worn outer tie rod ends have been replaced before proceeding further. 10. Verify all other steering linkage connections are tightened to their torque specifications. 11. Grease both outer tie rod ends (even if the outer tie rod is new). Apply sufficient grease to each tie rod end until grease is seen purging from the joint at the dust seal. 12. Align the vehicle front end. Adjust to specifications. 13. Road test the vehicle and verify the shimmy condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Damper: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads > Page 12931 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Damper: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads Steering Damper: All Technical Service Bulletins Steering - Front End Shimmy On Rough Roads NUMBER: 22-005-06 GROUP: Tire & Wheels DATE: October 07, 2006 SUBJECT: Front End Shimmy On 4x4 Vehicles When Traveling Over Rough Surfaces In The Road OVERVIEW: This bulletin involves verifying the condition of the vehicle front suspension and steering components, and adjusting the front tire pressure. MODELS: 2003 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to four wheel drive (4x4) 2500 and 3500 model vehicles. SYMPTOM/CONDITION: The customer may experience a self sustaining vibration (shimmy) felt in the front end of the vehicle after striking a bump or pothole. DIAGNOSIS: If the customer experiences the above condition perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on an alignment rack (drive-on lift). 2. Verify the road tires are correctly sized and the tire tread is not excessively worn. Replace any worn tire before proceeding. Any new or old replacement tire should be equal to the original tires that came with the vehicle when it was new. Tire wear is not covered by the vehicle warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Damper: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads > Page 12937 3. Set the tire pressure for the FRONT TIRES to the following specification, regardless of the load being carried by the vehicle. 4. Set the tire pressure for the REAR TIRES as recommended for the vehicle configuration and load that is being carried at the time. 5. Verify that the steering damper is operating correctly. a. Unbolt the end of the damper at the axle end. b. Cycle the damper rod by hand. c. There should be resistance to motion in both directions of the damper rod. d. Replace the damper if no resistance is present. 6. Verify both outer tie rod ends dust covers are not worn. a. Attempt to rotate the dust cover by hand. b. If the dust cover on an outer tie rod end can be rotated, or is free and loose, then replace the tie rod (regardless of joint wear). 7. Inspect each outer tie rod end for internal wear. a. Maximum allowed wear (joint travel) for a tie rod end is 1.15 mm (0.045 in.). b. Install a dial indicator to the tie rod end (in-line with the vertical stud of the tie rod end). c. With a pry bar placed between the steering linkage and the axle tube, pry upwards while measuring the amount of joint travel (wear). d. Measure the amount of wear in the other outer tie rod end joint. e. If wear (joint travel) in either outer tie rod end is greater than 1.15 mm (0.045 in.), then replace the worn tie rod end. 8. Verify the torque on each outer tie rod end stud nut. The nut should be tightened to 122 Nm (90 ft. lbs.). 9. Make sure any worn outer tie rod ends have been replaced before proceeding further. 10. Verify all other steering linkage connections are tightened to their torque specifications. 11. Grease both outer tie rod ends (even if the outer tie rod is new). Apply sufficient grease to each tie rod end until grease is seen purging from the joint at the dust seal. 12. Align the vehicle front end. Adjust to specifications. 13. Road test the vehicle and verify the shimmy condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Damper: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads > Page 12938 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects Technical Service Bulletin # H46 Date: 090609 Recall - Steering Linkage Defects Revised May 2009 Dealer Service Instructions for: Safety Recall H46 - Mopar Steering Linkage NOTE: The service procedure for this recall has been revised and additional labor operations have been added. All previous copies of Safety Recall H46 should be discarded from your files. Models 2003-2004 (DR) Dodge Truck 4x4 (2500/3500 series) 2005 (DH) Dodge Truck 4x4 (2500/3500 series) 2006-2009 (DH) Dodge Truck 4x4 (2500/3500 series or 1500 Mega Cab) 2006-2009 (D1) Dodge Truck 4x4 (3500 series) 2007-2009 (DC) Dodge Truck (3500 series cab chassis) IMPORTANT: This recall only applies to vehicles that had certain Mopar service parts steering components installed. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject During a prior service appointment, a Mopar service parts steering linkage was installed on about 19,400 of the above vehicles. The drag link inner joint may fracture under certain driving conditions. This could result in a loss of steering control and cause a crash without warning. Also, the steering damper bracket at the tie rod tube may loosen. This could allow the bracket to slide on the tube and may cause increased vehicle turning radius. Repair The steering linkage must be inspected and some steering linkage components may need to be replaced. NOTE: The initial steering linkage inspection process can be done by write up personnel in the write up area (see Step 1 of the service procedure). Vehicles found with original style steering linkage can be immediately returned to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12944 Parts Information Special Tools The special tools may be required to perform this repair: Completion Reporting and Reimbursement Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12945 Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. FOR VEHICLES INSPECTED IN THE WRITE UP AREA: Enter "INSPECT" in the part number section of your claim with a quantity of one (1). Enter $5.00 WITH NO MARK-UP for reimbursement of steering linkage inspection performed in the write up area. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12946 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure NOTE: The initial steering linkage inspection process (Step 1 of the service procedure) can be done by write up personnel in the write up area. Vehicles found with the steering linkage shown in Figure 1 can be immediately returned to the customer. See the "Completion Reporting and Reimbursement" section of this recall for special claims processing information. 1. Look under the front of the vehicle and inspect the steering linkage at the steering damper mounting point: > If the steering damper mounts to the tie rod tube as shown in Figure 1, the steering linkage is good. Return the vehicle to the customer. No further action is required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12947 > If the steering damper mounts to the tie rod tube as shown in Figure 2, the vehicle will require further inspection and/or repair by a technician. The vehicle should be assigned to a technician and the technician should continue with Step 2 of this procedure. 2. Lift the vehicle on a hoist and inspect the steering linkage drag link for a white part number tag (Figure 3): > If the steering linkage drag link does not have a white part number tag, continue with Step 3 of this procedure. ^ If the steering linkage drag link has a white part number tag: > For 2009 model year trucks, continue with Step 9 of this procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12948 > For 2003 through 2008 model year trucks, continue with Step 5 of this procedure. 3. Inspect the steering damper bracket to tie rod tube mounting u-bolt nuts by putting a 13 mm box-end wrench onto the nut (Figure 4): > If a 13 mm wrench fits the steering damper bracket mounting u-bolt nuts, the bracket and fasteners must be replaced. Continue with Step 4 of this procedure. > If a 13 mm wrench does not fit the steering damper bracket mounting u-bolt nuts, the bracket does not require replacement. Continue with Step 5 of this procedure. 4. Replace the steering damper bracket and fasteners using the following procedure: a. Remove and save the steering damper-to-damper bracket mounting nut (Figure 5). b. Disconnect the steering damper eyelet from the steering damper bracket. c. Remove and discard the four steering damper bracket nuts, two u-bolts and the steering damper bracket (Figure 5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12949 d. Place the new steering damper carriage bolt through the square hole in the new steering damper bracket. e. Place the new steering damper bracket assembly onto the tie rod tube at the flat spot area on the tube and install the new u-bolts and nuts. Lightly snug the nuts to hold the steering damper bracket in position. f. Center the new steering damper bracket on the flattened area of the tie rod tube. g. Evenly tighten the four steering damper bracket u-bolt nuts to 25 ft. lbs. (34 N.m). Then tighten the four u-bolt nuts to 45 ft. lbs. (61 N.m). h. Connect the steering damper to the steering damper carriage bolt. i. Install the steering damper-to-damper bracket mounting nut and tighten to 75 ft. lbs. (100 N.m). j. Continue with Step 5 of this procedure. 5. For 2009 model year trucks, continue with Step 6 of this procedure. For 2003 through 2008 model year trucks, inspect the pitman arm part number (Figure 6): > If the part number cast into the bottom side of the pitman arm is 68039930AA the pitman arm does not require replacement. > Steering linkage with a white part number tag, continue with Step 9 of this procedure. > Linkage without a white part number tag, replace the inner drag link joint. Continue with Step 6 of this procedure. > If the part number cast into the bottom side of the pitman arm is 52106836AB, or is not legible: > Steering linkage without a white part number tag, replace the inner drag link joint and pitman arm. Continue with Step 7 of this procedure. > Steering linkage with a white part number tag, replace the pitman arm. Continue with Step 8 of this procedure. 6. Replace the inner drag link joint using the following procedure: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12950 a. Loosen both drag link adjuster sleeve clamp nuts (Figure 7). b. Remove and discard the inner drag link joint to pitman arm nut (Figure 7). c. Use Special Tool C-4150A to separate the steering inner drag link joint from the pitman arm (Figure 8). d. While counting the number of turns, unscrew the steering inner drag link joint from the drag link adjuster sleeve (right handed threads) and discard the drag link inner joint. CAUTION: Do not allow the drag link adjuster sleeve to turn while unscrewing the inner drag link joint. e. Screw in the new inner drag link joint into the drag link adjuster sleeve the same number of turns counted in step 6d. of this procedure. f. Connect the steering inner drag link joint to the pitman arm. g. Install the new steering inner drag link joint nut and tighten the nut to 100 ft. lbs. (135 N.m). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12951 h. With the wheels in the straight ahead position, make sure that both inner and outer steering drag link joint caps are centered over the joint ball stud (Figure 9). CAUTION: Failure to center the drag link inner and outer joint caps over the joint ball studs before tightening the drag link adjuster sleeve clamps could cause joint failure. i. With the adjuster sleeve clamps rotated 45 degrees forward, tighten both drag link adjuster sleeve clamp nuts to 45 ft. lbs. (61 N.m). CAUTION: The drag link adjuster sleeve clamp tabs must be pointing approximately 45 degrees forward before tightening (as shown in Figure 10). Do not allow the adjuster sleeve clamp tabs to hang straight down. j. Lower the vehicle from the hoist. k. Drive the vehicle to verify that the steering wheel is straight. > If the steering wheel is turned to the left, shorten the drag link at the adjuster sleeve located on the drag link. > If the steering wheel is turned to the right, lengthen the drag link at the adjuster sleeve located on the drag link. l. Repeat Step 6k. until steering wheel is straight. m. Continue with Step 9 of this procedure. 7. Replace the inner drag link joint and pitman arm using the following procedure: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12952 a. Loosen both drag link adjuster sleeve clamp nuts (Figure 7). b. Remove and save the pitman arm retaining nut located on the steering gear output shaft. c. Install pitman arm puller (Special Tool 9615) onto the steering gear output shaft (Figure 11). CAUTION: Failure to use the correct pitman arm puller could cause damage to the steering gear. d. Tighten the pitman arm puller forcing screw until the pitman arm separates from the steering gear output shaft (Figure 11). e. While counting the number of turns, unscrew the steering inner drag link joint (with pitman arm still attached) from the drag link adjuster sleeve (right handed threads) and discard the pitman arm and inner drag link joint. CAUTION: Do not allow the drag link adjuster sleeve to turn while unscrewing the inner drag link joint. f. Screw in the new steering inner drag link joint into the drag link adjuster sleeve the same number of turns counted in step 7e. of this procedure. g. Install the new pitman arm and retaining nut onto the steering gear output shaft. Tighten the pitman arm nut to 225 ft. lbs. (300 N.m). h. Connect the steering inner drag link joint to the pitman arm. i. Install the new steering inner drag link joint nut and tighten the nut to 100 ft. lbs. (135 N.m). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12953 j. With the wheels in the straight ahead position, make sure that both inner and outer steering drag link joint caps are centered over the joint ball stud (Figure 12). CAUTION: Failure to center the drag link inner and outer joint caps over the joint ball studs before tightening the drag link adjuster sleeve clamps could cause joint failure. k. With the adjuster sleeve clamps rotated 45 degrees forward, tighten the drag link adjuster sleeve clamp nuts to 45 ft. lbs. (61 N.m).lbs. CAUTION: The drag link adjuster sleeve clamp tabs must be pointing approximately 45 degrees forward before tightening (as shown in Figure 10). Do not allow the adjuster sleeve clamp tabs to hang straight down. l. Lower the vehicle from the hoist. m. Drive the vehicle to verify that the steering wheel is straight. > If the steering wheel is turned to the left, shorten the drag link at the adjuster sleeve located on the drag link. > If the steering wheel is turned to the right, lengthen the drag link at the adjuster sleeve located on the drag link. n. Repeat Step 7m. until steering wheel is straight. o. Continue with Step 9 of this procedure. 8. Replace the pitman arm using the following procedure: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12954 a. Remove and discard the inner drag link joint nut (Figure 13). b. Use Special Tool C-4150A to separate the steering inner drag link joint from the pitman arm (Figure 14). CAUTION: Use extreme care not to tear, nick or damage the inner drag link joint rubber boot. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12955 d. Install pitman arm puller (Special Tool 9615) onto the steering gear output shaft (Figure 15). CAUTION: Failure to use the correct pitman arm puller could cause damage to the steering gear. e. Tighten the pitman arm puller forcing screw until the pitman arm separates from the steering gear output shaft (Figure 15). f. Install the new pitman arm. g. Install the pitman arm retaining nut onto the steering gear output shaft. Tighten the pitman arm nut to 225 ft. lbs. (300 N.m). h. Connect the steering inner drag link joint to the pitman arm. i. Install the new steering inner drag link joint nut and tighten the nut to 100 ft. lbs. (135 N.m). j. Lower the vehicle from the hoist. k. Drive the vehicle to verify that the steering wheel is straight. > If the steering wheel is turned to the left, shorten the drag link at the adjuster sleeve located on the drag link. ^ If the steering wheel is turned to the right, lengthen the drag link at the adjuster sleeve located on the drag link. l. Repeat Step 8k. until steering wheel is straight. m. Continue with Step 9 of this procedure. 9. Verify the lower surface of the left outer tie rod socket is parallel to the upper surface of the left knuckle attaching arm using the following procedure: a. Loosen the tie rod tube adjuster sleeve clamps. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12956 b. Rotate the left tie rod until the bottom of the tie rod socket is parallel to the top of the left steering knuckle arm (Figure 16). c. Tighten the tie rod adjuster sleeve clamp nuts to 45 ft.lbs. (61 N.m). CAUTION: Failure to align the left tie rod end parallel to the steering knuckle could cause tie rod end damage. d. Return the vehicle to the customer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Damper: > H46 > Jun > 09 > Recall - Steering Linkage Defects > Page 12957 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Service and Repair > Removal Steering Damper: Service and Repair Removal REMOVAL 1. Remove the steering damper mounting nuts and bolts (6) at axle. 2. Remove the steering damper mounting nuts and bolts (1) at linkage. 3. Remove the steering damper shock (2) from the linkage using special tool 9360 puller. 4. Remove the damper (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Service and Repair > Removal > Page 12960 Steering Damper: Service and Repair Installation INSTALLATION 1. Install the steering damper (5) on the axle. Tighten nut (6) to 95 Nm (75 ft. lbs.). 2. Install the steering damper (2) on the linkage. Tighten nut (1) to 81 Nm (60 ft. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Service and Repair > Pitman Shaft Seal - Link/Coil Steering Gear Seal: Service and Repair Pitman Shaft Seal - Link/Coil Gas GAS 1. Separate the pitman arm from the gear box. 2. Clean exposed end of pitman shaft and housing with a wire brush. 3. Rotate the steering wheel from stop to stop and count the number of turns. 4. Center the steering wheel by rotating it from the stop back 1 1/2 turns to achieve center position. 5. Remove the pitman shaft cover bolts. NOTE: The pitman shaft will not clear the housing if it is not centered. 6. Remove the pitman shaft from the gear. 7. Remove dust seal from the housing with the seal remover adapter tool 8990 (2). CAUTION: Use care not to score the housing bore when prying out seals and washer. 8. Remove retaining ring with snap ring pliers. 9. Remove washer from the housing. NOTE: Tighten the slide hammer seal remover adapter tool 8990 into the seal using wrenches, in order to make a tight fit to pull the seal out. If this is not performed the seal may tear on the removal making it difficult to remove. 10. Remove oil seal from the housing with the seal remover adapter tool 8990 (2) along with slide hammer puller C-3752. Diesel DIESEL 1. Separate the pitman arm from the gear box. 2. Remove the steering gear box. 3. Install the steering gear in a soft jawed bench vise. 4. Clean exposed end of pitman shaft and housing with a wire brush. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Service and Repair > Pitman Shaft Seal - Link/Coil > Page 12966 5. Rotate the input shaft with a 12 point socket (2) from stop to stop and count the number of turns. 6. Center the input shaft (4) by rotating it from the stop 1/2 of the total amount of turns. 7. Remove the pitman shaft cover bolts. NOTE: The pitman shaft will not clear the housing if it is not centered. 8. Remove the pitman shaft from the gear (1). 9. Remove dust seal from the housing with the seal remover adapter tool 8990 (2). CAUTION: Use care not to score the housing bore when prying out seals. 10. Remove retaining ring with snap ring pliers. 11. Remove washer from the housing. NOTE: Tighten the slide hammer seal remover adapter tool 8990 into the seal using wrenches, in order to make a tight fit to pull the seal out. If this is not performed the seal may tear on the removal making it difficult to remove. 12. Remove oil seal from the housing with the seal remover adapter tool 8990 (2) along with slide hammer puller C-3752. Gas GAS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Service and Repair > Pitman Shaft Seal - Link/Coil > Page 12967 NOTE: Generous amounts of the high temperature grease from the seal kit should be applied to areas between the pitman shaft bearing and oil seals and also between the dust seals and snap ring. 1. Coat the oil seal and washer with high temp grease. NOTE: Install the oil seal with the lip facing inward. Flat side of the oil seal should be against the washer. 2. Install the oil seal with pitman shaft seal installer tool 8989 driver (2) and C-4171 handle (1). 3. Install backup washer. 4. Install the retainer ring with snap ring pliers. 5. Coat the dust seal with high temp grease. 6. Install the dust seal with a driver (2) and handle (1). 7. Install pitman shaft protective seal protector 8993 (2) over the shaft. 8. Install the pitman shaft into the steering gear until it fully seats into the bearing. 9. Install the new cover bolts and tighten to 68 Nm (50 ft. lbs.). 10. Install the pitman arm. Diesel DIESEL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Service and Repair > Pitman Shaft Seal - Link/Coil > Page 12968 NOTE: Generous amounts of the high temperature grease from the seal kit should be applied to areas between the pitman shaft bearing and oil seals and also between the dust seals and snap ring. 1. Coat the oil seal and washer with high temp grease. NOTE: Install the oil seal with the lip facing inward. Flat side of the oil seal should be against the washer. 2. Install the oil seal with pitman shaft seal installer 8989 driver (2) and C-4171 handle (1). 3. Install backup washer. 4. Install the retainer ring with snap ring pliers. 5. Coat the dust seal with high temp grease. 6. Install the dust seal with pitman shaft seal installer 8989 driver (2) and C-4171 handle (1). 7. Install pitman shaft protective seal protector 8993 (2) over the shaft (1). 8. Install the pitman shaft into the steering gear until it fully seats into the bearing. 9. Install the new cover bolts and tighten to 68 Nm (50 ft. lbs.). 10. Install the steering gear. 11. Install the pitman arm. 12. Perform a wheel alignment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Service and Repair > Pitman Shaft Seal - Link/Coil > Page 12969 Steering Gear Seal: Service and Repair Steering Gear Input Shaft Seal - Link/Coil Removal REMOVAL 1. Remove the steering gear from the vehicle. CAUTION: Do not overtighten the vise on the gear case. This may affect the adjustment 2. Mount the steering gear upside down over a drain pan in a soft jawed vise. 3. Place a drain pan under the gear and rotate the input shaft back and forth several times lock-to-lock to discharge the fluid from the steering gear 4. Drain all the remaining fluid from the gear. 5. Rotate the input shaft (4) from stop to stop and count the number of turns using a 12 point socket (2). NOTE: The pitman shaft will not clear the housing if it is not centered. 6. Center the input shaft (4) by rotating it from the stop back 1 1/2 turns to achieve center position. 7. Remove the pitman shaft. 8. Remove the four bolts securing the valve housing (1). 9. Remove the valve housing (1) from the steering gear (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Service and Repair > Pitman Shaft Seal - Link/Coil > Page 12970 10. Remove the valve housing (1) and wormshaft assembly from the steering gear housing and place the valve housing in a soft jawed vise. 11. Remove the retainer ring (3) set screw (1) from the valve housing. 12. Using special tool retainer ring wrench 8988 (1) to remove the steering gear worm thrust bearing retainer ring. 13. Separate the wormshaft assembly from the valve housing, Then remove the wormshaft assembly from the vise. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Service and Repair > Pitman Shaft Seal - Link/Coil > Page 12971 14. Remove the dust seal (3) with a pick (1). CAUTION: Use care not to score the housing bore when removing seals. 15. Remove the snap ring (2) with snap ring pliers (1). 16. Using slide hammer puller C-3752 (1) with seal remover adapter 8990 (1) remove the oil seal. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Service and Repair > Pitman Shaft Seal - Link/Coil > Page 12972 1. Inspect the piston teflon seals for damage. Replace if needed. NOTE: To replace the teflon seals, use a pick to remove the teflon O-ring and the rubber O-ring underneath. Install a new rubber O-ring in the piston seal grove and a new teflon O-ring over the top of it. 2. Install the valve into the valve housing (1). 3. Thread the retainer ring into the valve housing (1). Tighten to 97 Nm (72 ft. lbs.). NOTE: It is very important to make sure to compensate for the added length of the torque wrench when torquing to proper specifications. 4. Install the retainer ring set screw. Tighten to 2.26 Nm (20 in. lbs.) 5. Clean the steering gear housing. CAUTION: Valve assembly must be centered to the housing (1). 6. Install the valve assembly (2) into the steering gear. Tighten the new bolts to 54 Nm (40 ft. lbs.) 7. Install the input shaft seal protector 8986 (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Service and Repair > Pitman Shaft Seal - Link/Coil > Page 12973 8. Coat the new seal in high temp grease and Install the new oil seal using the input shaft seal installer tool 8987 driver (2) and C-4171 handle (3). NOTE: Drive the oil seal into the housing until the outer edge does not quite clear the snap ring groove. 9. Insert the snap ring into the housing. Using the input shaft seal installer 8987 driver (2) and C-4171 handle (3) push the snap ring and oil seal together until the snap ring seats in the groove. NOTE: Generous amounts of the high temperature grease from the seal kit should be applied to areas between the pitman shaft bearing and oil seals and also between the dust seals and snap ring. 10. Install the new dust seal using high temp grease, special tool C-4171 (handle) (3) and 8987 (driver) (2). 11. Check to make sure the gear is centered in the middle tooth (1) before installing the pitman shaft. 12. Install the pitman shaft into the steering gear. 13. Perform over-center meshload adjustment. 14. Install the steering gear to the vehicle. 15. Perform a wheel alignment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations Steering Mounted Controls Communication Module: Locations Component ID: 212 Component : MODULE-STEERING CONTROL Connector: Name : MODULE-STEERING CONTROL C1 Color : WHITE # of pins : 6 Pin Description Circuit 1 GROUND Z909 20BK 2 RADIO CONTROL MUX X20 20GY/WT 3 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 4 S/C SWITCH NO. 1 SIGNAL V37 20VT 5 S/C SWITCH RETURN V937 20VT/BR 6 HORN SWITCH SENSE X3 20DG/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12977 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12978 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12979 Connector: Name : MODULE-STEERING CONTROL C2 Color : BLACK # of pins : 2 Qualifier : (PREMIUM) Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12980 2 RADIO CONTROL MUX X20 22GY/WT 2 RADIO CONTROL MUX X20 22GY/WT Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12981 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12982 Connector: Name : MODULE-STEERING CONTROL C3 Color : # of pins : 4 Pin Description Circuit 1 HORN SWITCH SENSE X3 20DG/VT 2 S/C SWITCH RETURN V937 22DB/DG 2 SENSOR GROUND K900 22DB/DG 3 S/C SWITCH NO. 1 SIGNAL V37 22VT 4 S/C SWITCH NO. 2 SIGNAL V38 22VT/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12983 Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12984 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12985 Connector: Name : MODULE-STEERING CONTROL C4 Color : YELLOW # of pins : 4 Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R61 20LG/VT 2 DRIVER SQUIB 2 LINE 2 R63 20LG/WT 3 DRIVER SQUIB 1 LINE 1 R43 20LG/BR 4 DRIVER SQUIB 1 LINE 2 R45 20LG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12986 Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12987 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12988 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12989 Steering Mounted Controls Communication Module: Diagrams Component ID: 212 Component : MODULE-STEERING CONTROL Connector: Name : MODULE-STEERING CONTROL C1 Color : WHITE # of pins : 6 Pin Description Circuit 1 GROUND Z909 20BK 2 RADIO CONTROL MUX X20 20GY/WT 3 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 4 S/C SWITCH NO. 1 SIGNAL V37 20VT 5 S/C SWITCH RETURN V937 20VT/BR 6 HORN SWITCH SENSE X3 20DG/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12990 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12991 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12992 Connector: Name : MODULE-STEERING CONTROL C2 Color : BLACK # of pins : 2 Qualifier : (PREMIUM) Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12993 2 RADIO CONTROL MUX X20 22GY/WT 2 RADIO CONTROL MUX X20 22GY/WT Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12994 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12995 Connector: Name : MODULE-STEERING CONTROL C3 Color : # of pins : 4 Pin Description Circuit 1 HORN SWITCH SENSE X3 20DG/VT 2 S/C SWITCH RETURN V937 22DB/DG 2 SENSOR GROUND K900 22DB/DG 3 S/C SWITCH NO. 1 SIGNAL V37 22VT 4 S/C SWITCH NO. 2 SIGNAL V38 22VT/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12996 Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12997 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12998 Connector: Name : MODULE-STEERING CONTROL C4 Color : YELLOW # of pins : 4 Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R61 20LG/VT 2 DRIVER SQUIB 2 LINE 2 R63 20LG/WT 3 DRIVER SQUIB 1 LINE 1 R43 20LG/BR 4 DRIVER SQUIB 1 LINE 2 R45 20LG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 12999 Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 13000 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 13001 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Service and Repair > Upper Steering Coupling Steering Shaft Coupler: Service and Repair Upper Steering Coupling Removal REMOVAL 1. Disconnect the negative battery cable. NOTE: The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative methods of locking the steering wheel for service will have to be used. 2. Lock the steering wheel with the tire in the straight position. 3. Remove and discard the lower pinch bolt. 4. Lower the steering coupler shaft from the column. 5. Remove the upper steering coupling shaft (2) seal by pushing in the four tags (1) securing it to the panel. 6. Remove and discard the lower coupler pinch bolt (1) from the lower steering coupling shaft (1). 7. Remove the upper steering coupling shaft (3) from the vehicle. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Service and Repair > Upper Steering Coupling > Page 13006 1. Install the upper steering coupling shaft (3) to the vehicle. 2. Install the upper steering coupling shaft seal (2) by pushing it in securing the four tangs (1) to the panel. NOTE: A new steering coupling shaft pinch bolt for the upper and lower shafts must be used. 3. Install the steering coupler shaft (1) to the column. 4. Install the upper pinch bolt (3) use new bolt and tighten to 57 N.m (42 ft.lbs). 5. Install the shaft to the lower coupler (1). 6. Install the lower pinch bolt (1) use new bolt and tighten to 57 N.m (42 ft.lbs). 7. Unlock the steering wheel. 8. Reconnect the negative battery cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Service and Repair > Upper Steering Coupling > Page 13007 Steering Shaft Coupler: Service and Repair Lower Steering Coupling Removal 4X4 HD 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. NOTE: The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative methods of locking the steering wheel for service will have to be used. 3. Lock the steering wheel with the tire in the straight position. 4. Remove the left front tire and wheel assembly. 5. Remove and discard the upper coupler pinch bolt (1). 6. Remove and discard the lower coupler pinch bolt (2). 7. Remove the lower steering shaft coupler (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Service and Repair > Upper Steering Coupling > Page 13008 Installation 4X4 HD 1. Install the coupler (2) to the steering gear (3). 2. Install the coupler (3) to the intermediate shaft (2). NOTE: New pinch bolts must be used for reinstallation. 3. Install the lower pinch bolt (3) and tighten to 28 Nm (250 in. lbs.). 4. Install the upper pinch bolt (1) and tighten to 57 Nm (42 ft. lbs.). 5. Install the left front tire and wheel assembly. 6. Lower the vehicle. 7. Reconnect the negative battery cable. 8. Unlock the steering wheel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Removal Steering Wheel: Service and Repair Removal REMOVAL 1. Disable and remove the driver's side airbag. 2. Partially remove the steering wheel bolt and leave the bolt in the column. 3. Install puller CJ98-1 (2) or equivalent using the top of the bolt to push on. 4. Remove and discard the steering wheel bolt. 5. Remove the steering wheel (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Removal > Page 13013 Steering Wheel: Service and Repair Installation INSTALLATION NOTE: Do not reuse the old steering wheel bolt (a new bolt must be used) 1. Install steering wheel to the column NOTE: Be certain that the steering wheel mounting bolt is tightened to the proper torque specification to ensure proper clockspring operation. 2. Install the new steering wheel bolt. Tighten the bolt to 61 Nm (45 ft. lbs.). 3. Install the driver's side air bag. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Customer Interest for Tie Rod End: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads Tie Rod End: Customer Interest Steering - Front End Shimmy On Rough Roads NUMBER: 22-005-06 GROUP: Tire & Wheels DATE: October 07, 2006 SUBJECT: Front End Shimmy On 4x4 Vehicles When Traveling Over Rough Surfaces In The Road OVERVIEW: This bulletin involves verifying the condition of the vehicle front suspension and steering components, and adjusting the front tire pressure. MODELS: 2003 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to four wheel drive (4x4) 2500 and 3500 model vehicles. SYMPTOM/CONDITION: The customer may experience a self sustaining vibration (shimmy) felt in the front end of the vehicle after striking a bump or pothole. DIAGNOSIS: If the customer experiences the above condition perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on an alignment rack (drive-on lift). 2. Verify the road tires are correctly sized and the tire tread is not excessively worn. Replace any worn tire before proceeding. Any new or old replacement tire should be equal to the original tires that came with the vehicle when it was new. Tire wear is not covered by the vehicle warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Customer Interest for Tie Rod End: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads > Page 13023 3. Set the tire pressure for the FRONT TIRES to the following specification, regardless of the load being carried by the vehicle. 4. Set the tire pressure for the REAR TIRES as recommended for the vehicle configuration and load that is being carried at the time. 5. Verify that the steering damper is operating correctly. a. Unbolt the end of the damper at the axle end. b. Cycle the damper rod by hand. c. There should be resistance to motion in both directions of the damper rod. d. Replace the damper if no resistance is present. 6. Verify both outer tie rod ends dust covers are not worn. a. Attempt to rotate the dust cover by hand. b. If the dust cover on an outer tie rod end can be rotated, or is free and loose, then replace the tie rod (regardless of joint wear). 7. Inspect each outer tie rod end for internal wear. a. Maximum allowed wear (joint travel) for a tie rod end is 1.15 mm (0.045 in.). b. Install a dial indicator to the tie rod end (in-line with the vertical stud of the tie rod end). c. With a pry bar placed between the steering linkage and the axle tube, pry upwards while measuring the amount of joint travel (wear). d. Measure the amount of wear in the other outer tie rod end joint. e. If wear (joint travel) in either outer tie rod end is greater than 1.15 mm (0.045 in.), then replace the worn tie rod end. 8. Verify the torque on each outer tie rod end stud nut. The nut should be tightened to 122 Nm (90 ft. lbs.). 9. Make sure any worn outer tie rod ends have been replaced before proceeding further. 10. Verify all other steering linkage connections are tightened to their torque specifications. 11. Grease both outer tie rod ends (even if the outer tie rod is new). Apply sufficient grease to each tie rod end until grease is seen purging from the joint at the dust seal. 12. Align the vehicle front end. Adjust to specifications. 13. Road test the vehicle and verify the shimmy condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Customer Interest for Tie Rod End: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads > Page 13024 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tie Rod End: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads Tie Rod End: All Technical Service Bulletins Steering - Front End Shimmy On Rough Roads NUMBER: 22-005-06 GROUP: Tire & Wheels DATE: October 07, 2006 SUBJECT: Front End Shimmy On 4x4 Vehicles When Traveling Over Rough Surfaces In The Road OVERVIEW: This bulletin involves verifying the condition of the vehicle front suspension and steering components, and adjusting the front tire pressure. MODELS: 2003 - 2007 (DR/DH/D1/DC) Ram Truck (2500/3500) NOTE: This bulletin applies to four wheel drive (4x4) 2500 and 3500 model vehicles. SYMPTOM/CONDITION: The customer may experience a self sustaining vibration (shimmy) felt in the front end of the vehicle after striking a bump or pothole. DIAGNOSIS: If the customer experiences the above condition perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on an alignment rack (drive-on lift). 2. Verify the road tires are correctly sized and the tire tread is not excessively worn. Replace any worn tire before proceeding. Any new or old replacement tire should be equal to the original tires that came with the vehicle when it was new. Tire wear is not covered by the vehicle warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tie Rod End: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads > Page 13030 3. Set the tire pressure for the FRONT TIRES to the following specification, regardless of the load being carried by the vehicle. 4. Set the tire pressure for the REAR TIRES as recommended for the vehicle configuration and load that is being carried at the time. 5. Verify that the steering damper is operating correctly. a. Unbolt the end of the damper at the axle end. b. Cycle the damper rod by hand. c. There should be resistance to motion in both directions of the damper rod. d. Replace the damper if no resistance is present. 6. Verify both outer tie rod ends dust covers are not worn. a. Attempt to rotate the dust cover by hand. b. If the dust cover on an outer tie rod end can be rotated, or is free and loose, then replace the tie rod (regardless of joint wear). 7. Inspect each outer tie rod end for internal wear. a. Maximum allowed wear (joint travel) for a tie rod end is 1.15 mm (0.045 in.). b. Install a dial indicator to the tie rod end (in-line with the vertical stud of the tie rod end). c. With a pry bar placed between the steering linkage and the axle tube, pry upwards while measuring the amount of joint travel (wear). d. Measure the amount of wear in the other outer tie rod end joint. e. If wear (joint travel) in either outer tie rod end is greater than 1.15 mm (0.045 in.), then replace the worn tie rod end. 8. Verify the torque on each outer tie rod end stud nut. The nut should be tightened to 122 Nm (90 ft. lbs.). 9. Make sure any worn outer tie rod ends have been replaced before proceeding further. 10. Verify all other steering linkage connections are tightened to their torque specifications. 11. Grease both outer tie rod ends (even if the outer tie rod is new). Apply sufficient grease to each tie rod end until grease is seen purging from the joint at the dust seal. 12. Align the vehicle front end. Adjust to specifications. 13. Road test the vehicle and verify the shimmy condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tie Rod End: > 22-005-06 > Oct > 06 > Steering - Front End Shimmy On Rough Roads > Page 13031 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Page 13032 Tie Rod End: Testing and Inspection OUTER TIE ROD END NOTE: If the outer tie rod end is equipped with a lubrication fitting, grease the joint then road test the vehicle before performing test. 1. Raise the front of the vehicle. Place safety floor stands under both lower control arms as far outboard as possible. Lower the vehicle to allow the stands to support some or all of the vehicle weight. 2. Remove the front tires. 3. Mount a dial indicator solidly to the vehicle steering knuckle and then zero the dial indicator. 4. Position indicator plunger on the topside of the outer tie rod end. NOTE: The dial indicator plunger must be perpendicular to the machined surface of the outer tie rod end. 5. Position a pry bar in order to pry downwards on the outer tie rod end. 6. If the travel exceeds 0.5 mm (0.020 in.), replace the outer tie rod end. 7. If the outer tie rod end is within specs reinstall the front tires. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Linkage - Independent Front Suspension Tie Rod End: Service and Repair Linkage - Independent Front Suspension Removal - Outer Tie Rod End REMOVAL - OUTER TIE ROD END NOTE: Do not twist the boot anytime during removal or installation. 1. Loosen the jam nut (3). 2. Remove the outer tie rod end nut from the ball stud. 3. Separate the tie rod ball stud (1) from the knuckle with Remover 9360 (2). 4. Unthread the outer tie rod end (1) from the inner tie rod. Installation - Outer Tie Rod End INSTALLATION - OUTER TIE ROD END NOTE: Do not twist the boot at anytime during removal or installation. 1. Thread the outer tie rod end (3) onto the inner tie rod (2), to it's original position. 2. Install the outer tie rod end (3) into the steering knuckle. 3. Tighten the ball stud nut on the ball stud to 61 Nm (45 ft. lbs.) then an additional 90°. 4. Set wheel toe pattern. 5. Tighten jam nut (1) to 127 Nm (94 ft. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Linkage - Independent Front Suspension > Page 13035 Tie Rod End: Service and Repair Linkage - Link/Coil Removal REMOVAL 1. Remove tie rod nuts (1). 2. Remove tie rod from drag link and left knuckle with remover C-4150A. Installation INSTALLATION 1. Install tie rod (2) to the left steering knuckle and drag link. Install the nuts (1) and tighten to 54 Nm (40 ft. lbs.) Then an additional 90°. 2. Remove the supports and lower the vehicle to the surface. Center steering wheel and adjust toe. 3. After adjustment tighten tie rod adjustment sleeve clamp bolts to 61 Nm (45 ft. lbs.). NOTE: Position the clamp on the sleeve so retaining bolt is located on the bottom side of the sleeve. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front - Independent Front Suspension Ball Joint: Specifications Front - Independent Front Suspension Upper Ball Joint Wear Limit If the travel exceeds ................................................................................................................................... 0.5 mm (0.020 in.), replace the upper ball joint. Lower Ball Joint Wear Limit If the travel exceeds ................................................................................................................................... 0.5 mm (0.020 in.), replace the lower ball joint. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front - Independent Front Suspension > Page 13041 Ball Joint: Specifications Front - Link/Coil Lower Ball Joint Wear Limit If this reading is above ........................................................................................ 2.29 mm (0.090 in) then replacement of the lower ball joint is necessary. Upper Ball Joint If this reading is above ........................................................................................ 2.29 mm (0.090 in) then replacement of the lower ball joint is necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front - Independent Front Suspension Ball Joint: Testing and Inspection Front - Independent Front Suspension Upper Ball Joint UPPER BALL JOINT 1. Raise the front of the vehicle. Place safety floor stands under both lower control arms as far outboard as possible. Lower the vehicle to allow the stands to support some or all of the vehicle weight. 2. Remove the front tires. 3. Mount a dial indicator solidly to the frame and then zero the dial indicator. 4. Position dial indicator plunger on the topside of the upper ball joint. NOTE: The dial indicator plunger must be perpendicular to the machined surface of the ball joint. NOTE: Use care not to pry or tear the ball joint boot (5), when checking the free play. 5. Position a pry bar between the steering knuckle and the upper control arm. Pry upwards on the upper control arm. 6. If the travel exceeds 0.5 mm (0.020 in.), replace the upper ball joint. 7. If the upper ball joint is within specs reinstall the front tires. Lower Ball Joint LOWER BALL JOINT 1. Raise the front of the vehicle. Place safety floor stands under both lower control arms as far outboard as possible. Lower the vehicle to allow the stands to support some or all of the vehicle weight. 2. Mount a dial indicator solidly to the topside of the lower control arm and then zero the dial indicator. 3. Position the indicator plunger against the bottom surface of the steering knuckle. NOTE: The dial indicator plunger must be perpendicular to the machined surface of the steering knuckle. 4. Position a pry bar under the tire assembly. Pry upwards on the tire assembly. 5. If the travel exceeds 0.5 mm (0.020 in.), replace the lower ball joint. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front - Independent Front Suspension > Page 13044 Ball Joint: Testing and Inspection Front - Link/Coil Lower Ball Joint LOWER BALL JOINT To properly diagnose the lower ball joint two readings from the dial indicator are necessary, The two readings must be added together to find a total ball joint movement as identified in the steps below. 1. Raise and support the vehicle. 2. Attach a dial indicator (2) with the indicator resting on the flat part of the steering knuckle (1) by the lower ball stud. 3. Set the dial indicator (2) to zero. NOTE: Use care not to damage the upper ball joint grease seal (3). 4. Pry between the knuckle (4) and the axle tube yoke next to the upper ball joint (2), Record the reading on the dial indicator. This will be the first reading. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front - Independent Front Suspension > Page 13045 5. Set the dial indicator (2) back to zero. 6. Set up a jackstand (3) and use a long prybar (1) to lift the knuckle assembly 7. Pry upwards on the flat part of the steering knuckle (5) next to the ball joint stud and nut (2) using the jackstand as leverage. Record the reading on the dial indicator. This will be the second reading. 8. Add the two reading together for a total lower ball joint movement, If this reading is above 2.29 mm (0.090 in) then replacement of the lower ball joint is necessary. Upper Ball Joint UPPER BALL JOINT To properly diagnose the upper ball joint two readings from the dial indicator are necessary, The two readings must be added together to find a total ball joint movement as identified in the steps below. 1. Raise and support the vehicle. 2. Attach a dial indicator (3) with the indicator resting on either the front or back sides of the steering knuckle (4) as close to the upper ball joint (1) as possible. 3. Set the dial indicator(3) to zero. 4. Grab the tire by pushing in on the top of the tire and pulling out on the bottom of the tire. Record the reading on the dial indicator (3). This will be the first reading. 5. Set the dial indicator (3) back to zero. 6. Grab the tire by pulling in on the top of the tire and pushing out on the bottom of the tire. Record the reading on the dial indicator (3). This will be the second reading. 7. Add the two readings together for a total upper ball joint movement. If this reading is above 1.52 mm (0.060 in) then replacement of the upper ball joint is necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front - Independent Front Suspension Ball Joint: Service and Repair Front - Independent Front Suspension Removal REMOVAL 1. Raise vehicle and support the axle. 2. Remove the tire and wheel. 3. Remove the upper ball joint retaining nut. 4. Separate the upper ball joint (4) from the knuckle (6) using separator #9360 (5). 5. Remove the wheel speed sensor wire from the knuckle (HD) and from the upper control arm (LD). 6. Move the knuckle out of the way to allow ball joint removal tool access. 7. Remove the ball joint boot for removal. NOTE: It may be necessary to install a block of wood between the control arm and frame bracket to allow clearance for the ball joint press tool. NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. 8. Press the ball joint (4) from the upper control arm (3) using special tools C-4212-F (PRESS) (1), 9770-1 (Receiver) (2) and 9770-2 (Driver) (5). Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front - Independent Front Suspension > Page 13048 NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. 1. Install the ball joint (3) into the upper control arm (4) and press in using special tools C-4212-F (press) (1), 9652 (Driver) (2) and 8445-1 (Receiver) (5). 2. Install the upper ball joint into the knuckle. 3. Install the upper ball joint retaining nut and tighten to 54 Nm (40 ft. lbs.)(on 1500 series only an additional 90° turn is required) or 68 Nm (50 ft. lbs.)(HD). 4. Install the wheel speed sensor wire to the knuckle (HD) and to the upper control arm (LD). 5. Install the tire and wheel. 6. Remove the supports and lower the vehicle. 7. Perform a wheel alignment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front - Independent Front Suspension > Page 13049 Ball Joint: Service and Repair Front - Link/Coil Removal REMOVAL 1. Remove the steering knuckle. 2. Remove the axle shaft from the axle. 3. Remove lower snap ring from the lower ball joint. 4. Position special tool 8975-2 (RECEIVER) (2) and 8975-4 (DRIVER) (4) with tool C4212-F (PRESS)(1) as shown to remove lower ball stud. Installation INSTALLATION 1. Position special tool 8975-1 (DRIVER) (2) and 8975-3 (RECEIVER) (5) with C4212-F (PRESS)(1) as shown to install lower ball stud (3). 2. Install the axle shaft into the axle. 3. Install the steering knuckle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front - Independent Front Suspension > Page 13050 Removal REMOVAL 1. Remove the steering knuckle. 2. Remove the axle shaft from the axle. 3. Position special tool 6761 (RECEIVER) (2) and 8445-3 (DRIVER) (4) with C-4212-F (PRESS)(1) as shown to remove upper ball stud. Installation INSTALLATION 1. Position special tool 8445-2 (DRIVER) (2) and 8975-5 (RECEIVER) (5) with C-42121-F (PRESS)(1) as shown to install upper ball stud (3). 2. Install the axle shaft into the axle 3. Install the steering knuckle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Removal Control Arm Bushing: Service and Repair Removal Upper Control Arm Bushings - IFS (HD) UPPER CONTROL ARM BUSHINGS - IFS (HD) 1. Remove the upper control arm. 2. Secure the control arm in a soft jaw vise. NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. 3. Remove the bushing (3) from the upper control arm (5) using special tool C-4212F (PRESS) (1), 9777-3 (receiver) (4), and 9777-2 (driver) (2). Lower Control Arm Shock Bushing - IFS 4X4 LOWER CONTROL ARM SHOCK BUSHING - IFS 4X4 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Support the lower control arm outboard end. 4. Remove the caliper adapter with the caliper. 5. Remove the rotor. 6. Remove the upper ball joint retaining nut and separate the upper ball joint (4) from the knuckle (6) using separator 9360 (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Removal > Page 13056 7. Disconnect the wheel speed sensor wire (3) from the knuckle and upper control arm. 8. Remove the stabilizer link lower nut (1). 9. Remove the axle hub nut. 10. Remove the shock lower bolt/nut from the lower control arm (5) then move the shock out of the way to allow the C4212-F press (4) to used. NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. 11. Install special tools to press the bushing (3) out of the lower control arm (4) using special tools C-4212-F (Press) (1), 9653-1 (driver) (5) and 9653-2 (Receiver) (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Removal > Page 13057 Control Arm Bushing: Service and Repair Installation Upper Control Arm Bushings - IFS (HD) UPPER CONTROL ARM BUSHINGS - IFS (HD) 1. Install the bushing (3) into the control arm (5) using special tool C-4212F (PRESS) (1), 9770-1 (receiver) (2) and 9777-1 (driver) (4). 2. Remove the control arm from the vise. 3. Install the upper control arm. 4. Perform a wheel alignment. Lower Control Arm Shock Bushing - IFS 4X4 LOWER CONTROL ARM SHOCK BUSHING - IFS 4X4 NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. 1. Install the new shock bushing (3) into the lower control arm (4) using tools C-4212-F (Press) (1), 9653-3 (driver) (2), 9773 (Receiver) (5) will automatically set the depth of the bushing in the control arm. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Removal > Page 13058 2. Install the lower part of the shock (5) into the lower control arm shock bushing (7). 3. Install and position bolt (6) so head of bolt is facing rearward of vehicle and hand start nut. Tighten the bolt (6) & nut to 81 Nm (60 ft. lbs.). 4. Install the upper ball joint to the knuckle and install the retaining nut. 5. Install and tighten the axle hub nut. 6. Install the stabilizer link lower nut. 7. Reconnect the wheel speed sensor wiring to the knuckle and upper control arm. 8. Install the rotor. 9. Install the caliper adapter with the caliper. 10. Remove the support from the lower control arm outboard end. 11. Install the tire and wheel assembly. 12. Remove the support and lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember - Removal Front Cross-Member: Service and Repair Front Crossmember - Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the front skid plate (2 - if equipped). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember - Removal > Page 13064 3. On the 2WD models, remove the bolts (2) and remove the crossmember (1). 4. On the 4WD models, remove the bolts (1) and remove the crossmember (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember - Removal > Page 13065 Front Cross-Member: Service and Repair Front Crossmember - Installation INSTALLATION 1. Install the crossmember (1). 2. Install the bolts (2); - On light duty 2WD vehicles, tighten the bolts to 61 Nm (45 ft. lbs.). - On heavy duty 2WD vehicles, tighten the bolts to 75 Nm (55 ft. lbs.). 3. On 4WD models, install the crossmember (2). 4. Install the bolts (1) and tighten to 102 Nm (75 ft. lbs.). 5. Install the front skid plate, if equipped (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal Rear Cross-Member: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the transfer case skid plate (if equipped). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal > Page 13070 3. Support the transmission (1) with a transmission jack (2) or suitable lifting device. 4. 2WD Vehicles - Remove the transmission mount nuts (3). 5. Remove the bolts and remove the crossmember (2). 6. 4WD Vehicles - Remove the transmission mount nuts (5). 7. Remove the bolts (3) and remove the crossmember (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal > Page 13071 Rear Cross-Member: Service and Repair Installation INSTALLATION 1. On Light Duty Vehicles, install the crossmember (2) and the bolts (4). Tighten the bolts to 102 Nm (75 ft. lbs.). 2. Install the transmission mount nuts and tighten to 54 Nm (40 ft. lbs.). 3. On Heavy Duty Vehicles, install the crossmember (4) and the bolts (3). Tighten the bolts to 115 Nm (85 ft. lbs.). 4. Install the transmission mount nuts and tighten to 54 Nm (40 ft. lbs.). 5. Remove the transmission support (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal > Page 13072 6. Install the transfer case skid plate (3 - if equipped). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation > Description Front Steering Knuckle: Description and Operation Description DESCRIPTION The knuckle (1) is a single casting with legs machined for the upper and lower ball joints. The knuckle also has machined mounting locations for the front brake calipers and hub bearing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation > Description > Page 13077 Front Steering Knuckle: Description and Operation Operation OPERATION The steering knuckle pivot between the upper and lower ball joint. Steering linkage attached to the knuckle allows the vehicle to be steered. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front - Independent Front Suspension Front Steering Knuckle: Service and Repair Front - Independent Front Suspension Removal (LD) 4X2 & 4X4 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, rotor, shield and ABS wheel speed sensor if equipped. 4. Remove the tie rod end nut. Separate the tie rod from the knuckle with Remover 9360. 5. Remove the halfshaft nut (4X4 only). 6. Remove the upper ball joint nut. Separate the ball joint (4) from the knuckle (6) with Remover 9360 (5) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front - Independent Front Suspension > Page 13080 CAUTION: When installing puller 8677 to separate the ball joint, be careful not to damage the ball joint seal. 7. Remove the lower ball joint nut. Separate the ball joint from the knuckle with Remover 8677 (2). 8. Remove the steering knuckle (1) from the vehicle. 9. Remove the hub/bearing from the steering knuckle on the bench. Installation (LD) 4X2 & 4X4 CAUTION: The ball joint stud tapers must be CLEAN and DRY before installing the knuckle. Clean the stud tapers with mineral spirits to remove dirt and grease. NOTE: When installing hub/bearing with ABS brakes, position the speed sensor opening towards the front of the vehicle. 1. Install the hub/bearing to the steering knuckle (1) and tighten the bolts to 163 Nm (120 ft. lbs.). 2. Install the knuckle (1) onto the upper and lower ball joints. 3. Install the upper and lower ball joint nuts. Tighten the upper ball joint nut to 54 Nm (40 ft. lbs.) (an additional 90° turn is required) and the lower ball joint nut to 52 Nm (38 ft. lbs.)(an additional 90° turn is required). 4. Remove the hydraulic jack from the lower suspension arm (4). 5. Install the tie rod end and tighten the nut to 61 Nm (45 ft. lbs.). 6. Install the front halfshaft into the hub/bearing (if equipped). 7. Install the the halfshaft nut and tighten to 251 Nm (185 ft. lbs.) (if equipped). 8. Install the ABS wheel speed sensor (if equipped) and brake shield, rotor and caliper. 9. Install the wheel and tire assembly. 10. Remove the support and lower the vehicle. 11. Perform a wheel alignmen. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front - Independent Front Suspension > Page 13081 Front Steering Knuckle: Service and Repair Front - Link/Coil Removal REMOVAL 1. Remove the hub bearing. 2. Remove tie-rod or drag link end from the steering knuckle arm. 3. Remove the wheel speed sensor. 4. Loosen the upper ball stud nut.Do not remove the nut at this time. 5. Remove the lower ball joint nut. 6. Separate the lower ball joint (4) using special tool C-4150A separator (3). 7. Remove the upper ball joint nut. 8. Remove the steering knuckle (2). Installation INSTALLATION 1. Position the steering knuckle on the ball studs. 2. Install and tighten lower ball stud nut to 47 Nm (35 ft. lbs.) torque. 3. Install and tighten upper ball stud nut to 94 Nm (70 ft. lbs.) torque. 4. Retorque lower ball stud nut to 190-217 Nm (140-160 ft. lbs.) torque. 5. Install the hub bearing. 6. Install tie-rod or drag link end onto the steering knuckle arm. 7. Install the wheel speed sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Removal Lateral Stabilizer Rod: Service and Repair Removal REMOVAL 1. Raise and support the axle. 2. Remove the track bar bolts (2) and nuts (3). 3. Remove the track bar (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Removal > Page 13086 Lateral Stabilizer Rod: Service and Repair Installation INSTALLATION 1. Install the track bar (1). 2. Install the new bolts (2) and nuts (3). Tighten to 203 Nm (150 ft lbs.). 3. Remove the supports under the axle and lower the vehicle to the ground. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set Steering Angle Sensor: Customer Interest ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set NUMBER: 08-044-06 GROUP: Electrical DATE: October 07, 2006 SUBJECT: DTC C1240 - Steering Angle Sensor Over Travel Performance OVERVIEW: This bulletin involves the diagnosis and possible replacement of the Steering Angle Sensor. MODELS: 2007 (DR) Ram Truck NOTE: This bulletin applies to vehicle equipped with the Electronic Stability Program (sales code BNB) and built prior to October 03, 2006 (MDH 1003XX). SYMPTOM/CONDITION: The customer may experience an illumination on the instrument cluster of the "ABS" (Anti-Lock Brake System) and/or the "ESP / BAS" (Electronic Stability Program / Brake Assist System) Warning Lights. Investigation may reveal the presence of Diagnostic Trouble Code (DTC) C1240 Steering Angle Sensor Over Travel Performance (SAS). DIAGNOSIS: 1. Perform the diagnostic test procedure for DTC C1240. This diagnostic procedure can be found on TechCONNECT: select the SERVICE INFO tab > 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 340/445E5P AWAL > DIAGNOSIS and TESTING > C1240 - Steering Angle Sensor Over Travel Performance (SAS). 2. If the diagnostic test procedure for DTC C1240 determines that the Steering Angle Sensor is at fault, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Before starting this procedure, be certain that the front wheels are in the straight-ahead position. 1. Replace the steering column clockspring. Refer to TechCONNECT for detailed service procedures: select the SERVICE INFO tab > 8 - ELECTRICAL > RESTRAINTS > CLOCKSPRING > REMOVAL and INSTALLATION. 2. Clear offsets by initializing the ABS ECU using StarSCAN. 3. Perform the ABS VERIFICATION TEST. This test can be found in: 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 3401445E5P AWAL > STANDARD PROCEDURE > ABS VERIFICATION TEST. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Technical Service Bulletins > Customer Interest for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set > Page 13096 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set Steering Angle Sensor: All Technical Service Bulletins ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set NUMBER: 08-044-06 GROUP: Electrical DATE: October 07, 2006 SUBJECT: DTC C1240 - Steering Angle Sensor Over Travel Performance OVERVIEW: This bulletin involves the diagnosis and possible replacement of the Steering Angle Sensor. MODELS: 2007 (DR) Ram Truck NOTE: This bulletin applies to vehicle equipped with the Electronic Stability Program (sales code BNB) and built prior to October 03, 2006 (MDH 1003XX). SYMPTOM/CONDITION: The customer may experience an illumination on the instrument cluster of the "ABS" (Anti-Lock Brake System) and/or the "ESP / BAS" (Electronic Stability Program / Brake Assist System) Warning Lights. Investigation may reveal the presence of Diagnostic Trouble Code (DTC) C1240 Steering Angle Sensor Over Travel Performance (SAS). DIAGNOSIS: 1. Perform the diagnostic test procedure for DTC C1240. This diagnostic procedure can be found on TechCONNECT: select the SERVICE INFO tab > 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 340/445E5P AWAL > DIAGNOSIS and TESTING > C1240 - Steering Angle Sensor Over Travel Performance (SAS). 2. If the diagnostic test procedure for DTC C1240 determines that the Steering Angle Sensor is at fault, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Before starting this procedure, be certain that the front wheels are in the straight-ahead position. 1. Replace the steering column clockspring. Refer to TechCONNECT for detailed service procedures: select the SERVICE INFO tab > 8 - ELECTRICAL > RESTRAINTS > CLOCKSPRING > REMOVAL and INSTALLATION. 2. Clear offsets by initializing the ABS ECU using StarSCAN. 3. Perform the ABS VERIFICATION TEST. This test can be found in: 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 3401445E5P AWAL > STANDARD PROCEDURE > ABS VERIFICATION TEST. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Angle Sensor: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set > Page 13102 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Diagrams Suspension Mode Switch: Diagrams Component ID: 461 Component : SWITCH-DISCONNECTING STABILIZER BAR Connector: Name : SWITCH-DISCONNECTING STABILIZER BAR Color : BLACK # of pins : 12 Pin Description Circuit 1 LOCKER SWITCH SUPPLY T537 20YL/LG 2 LOCKER SWITCH SENSE T535 20YL/BR 3 STABILIZER BAR SWITCH SENSE T531 20YL/TN 4 SWITCH SUPPLY T536 20YL/WT 5 LOCKER OPEN ILLUMINATION SENSE T532 20YL/GY 6 LOCKER REAR ILLUMINATION SENSE T533 20YL/LB 7 LOCKER FR/RR ILLUMINATION SENSE T534 20YL 8 STABILIZER BAR DISENGAGE ILLUMINATION SENSE T530 20YL/DG 9 STABILIZER BAR ENGAGE ILLUMINATION SENSE T529 20YL/LG 10 - 11 PANEL LAMPS DRIVER E11 20OR/DB 12 GROUND Z952 20BK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Rear Stabilizer Link: Service and Repair Rear Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the upper nut (2) at the frame bracket. 3. Remove the lower link nut (3) at the stabilizer bar (4). 4. Remove the link (1) from the bar. Installation INSTALLATION 1. Install the link (1) to the bar (4). 2. Install the lower link nut (3) at the stabilizer bar. Tighten the nuts to 38 Nm (27 ft.lbs). 3. Install the upper link nut (2) at the frame bracket. Tighten the bolts to 61 Nm (45 ft.lbs). 4. Lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Rear > Page 13111 Stabilizer Link: Service and Repair Front - Independent Front Suspension Removal 4X4 NOTE: It may be necessary to remove the other stabilizer link upper nut (4) in order to remove the link (5) being worked on from the vehicle. 1. Raise and support the vehicle. 2. Remove the lower nut (6). 3. Remove the upper nut, retainers and grommets (4). 4. Remove the stabilizer link (5) from the vehicle. Installation 4X4 1. Install the stabilizer link (5) to the vehicle. 2. Install the lower nut (6) and Tighten to 102 Nm (75 ft. lbs.). 3. Install the retainers, grommets and upper nut (4) and Tighten to 27 Nm (20 ft. lbs.). 4. Remove the support and lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Rear > Page 13112 Stabilizer Link: Service and Repair Front - Link/Coil Stabilizer Link STABILIZER LINK 1. Raise and support the vehicle. 2. Hold the stabilizer link (5) shafts with a wrench and remove the link nuts at the stabilizer bar (3). 3. Remove the retainers (1) and grommets (2) from the stabilizer bar links (5). 4. Remove the stabilizer bar link nuts from the axle brackets. 5. Remove the links (2) from the axle brackets with Puller C-3894-A (1). Stabilizer Link With Disconnecting Stabilizer Bar STABILIZER LINK WITH DISCONNECTING STABILIZER BAR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Rear > Page 13113 1. Raise and support the vehicle. 2. Hold the stabilizer link (1) shafts with a wrench and remove the link nuts (3) at the stabilizer bar (2). 3. Remove the stabilizer bar link nuts from the axle brackets (2). 4. Remove the links (1) from the axle brackets (2) with Puller 9360 (3). Stabilizer Link STABILIZER LINK 1. Install links (5) to the axle bracket (4) and tighten nut to 149 Nm (110 ft. lbs.). 2. Install links (5), retainers (1), grommets (2) and nuts to the stabilizer bar. Hold the link shaft with a wrench and tighten the nuts to 38 Nm (27 ft. lbs.). 3. Remove the supports and lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Rear > Page 13114 Stabilizer Link With Disconnecting Stabilizer Bar STABILIZER LINK WITH DISCONNECTING STABILIZER BAR 1. Install links (1) to the axle bracket (5) and tighten nut (4) to 149 Nm (110 ft. lbs.). 2. Install links (1) and nuts (3) to the stabilizer bar (2). Hold the link shaft with a wrench and tighten the nuts to 149 Nm (110 ft. lbs.). 3. Remove the supports and lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Diagrams Suspension Mode Switch: Diagrams Component ID: 461 Component : SWITCH-DISCONNECTING STABILIZER BAR Connector: Name : SWITCH-DISCONNECTING STABILIZER BAR Color : BLACK # of pins : 12 Pin Description Circuit 1 LOCKER SWITCH SUPPLY T537 20YL/LG 2 LOCKER SWITCH SENSE T535 20YL/BR 3 STABILIZER BAR SWITCH SENSE T531 20YL/TN 4 SWITCH SUPPLY T536 20YL/WT 5 LOCKER OPEN ILLUMINATION SENSE T532 20YL/GY 6 LOCKER REAR ILLUMINATION SENSE T533 20YL/LB 7 LOCKER FR/RR ILLUMINATION SENSE T534 20YL 8 STABILIZER BAR DISENGAGE ILLUMINATION SENSE T530 20YL/DG 9 STABILIZER BAR ENGAGE ILLUMINATION SENSE T529 20YL/LG 10 - 11 PANEL LAMPS DRIVER E11 20OR/DB 12 GROUND Z952 20BK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Description Suspension Spring ( Coil / Leaf ): Description and Operation Description DESCRIPTION The rear suspension system uses a multi-leaf springs and a solid drive axle. The forward end of the springs are mounted to the body rail hangers through rubber bushings. The rearward end of the springs are attached to the body by the use of shackles. The spring and shackles use rubber bushings. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Description > Page 13123 Suspension Spring ( Coil / Leaf ): Description and Operation Operation OPERATION The springs control ride quality and maintain vehicle ride height. The shackles allow the springs to change their length as the vehicle moves over various road conditions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front - Independent Front Suspension Suspension Spring ( Coil / Leaf ): Service and Repair Front - Independent Front Suspension Removal 4X4-COIL OVER 1. Remove the shock (1). 2. Install the shock assembly (3) in the Branick 7200(R) spring removal/installation tool or equivalent (1). 3. Compress the spring (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front - Independent Front Suspension > Page 13126 4. Position shock wrench 9362 (1), on shock shaft retaining nut. Next, insert 8 mm socket though Wrench onto hex located on end of shock shaft. While holding shock shaft from turning, remove nut from shock shaft using Wrench (1). 5. Remove the upper shock nut. 6. Remove the shock upper mounting plate. 7. Remove and inspect the upper spring isolator (2). 8. Remove the shock. Installation 4X4-COIL OVER 1. Position the shock (1) into the coil spring (3). 2. Install the upper isolator (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front - Independent Front Suspension > Page 13127 3. Install the upper shock mounting plate (2). 4. Install the shock upper mounting nut. 5. Install shock wrench 9362 (1) (on end of a torque wrench), on shock shaft retaining nut. Next, insert 8 mm socket though Wrench onto hex located on end of shock shaft. While holding shock shaft from turning, tighten nut using Wrench to 90 Nm (66 ft. lbs.) torque. 6. Decompress the spring (2). 7. Remove the shock assembly from the spring compressor tool (1). 8. Install the shock assembly (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front - Independent Front Suspension > Page 13128 Suspension Spring ( Coil / Leaf ): Service and Repair Front - Link/Coil Removal REMOVAL 1. Raise and support the vehicle. Position a hydraulic jack under the axle to support it. 2. Paint or scribe alignment marks on lower suspension arm cam adjusters and axle bracket for installation reference. 3. Remove the upper suspension arm and loosen lower suspension arm bolts. 4. Mark and disconnect the front propeller shaft from the axle 4x4 models. 5. Disconnect the track bar from the frame rail bracket. 6. Disconnect the drag link from pitman arm. 7. Disconnect the stabilizer bar link and shock absorber from the axle. 8. Lower the axle until the spring is free from the upper mount. Remove the coil spring. Installation INSTALLATION 1. Position the coil spring on the axle pad. 2. Raise the axle into position until the spring seats in the upper mount. 3. Connect the stabilizer bar links and shock absorbers to the axle bracket. Connect the track bar to the frame rail bracket. 4. Install the upper suspension arm. 5. Install the front propeller shaft to the axle 4x4 model. 6. Install drag link to pitman arm and tighten nut to specifications. Install new cotter pin. 7. Remove the supports and lower the vehicle. 8. Tighten the following suspension components to specifications: - Link to stabilizer bar nut. - Lower shock bolt. - Track bar bolt at axle shaft tube bracket. - Upper suspension arm nut at axle bracket. - Upper suspension nut at frame bracket. - Align lower suspension arm reference marks and tighten cam nut. - Lower suspension nut at frame bracket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front - Independent Front Suspension > Page 13129 Suspension Spring ( Coil / Leaf ): Service and Repair Rear Removal REMOVAL 1. Raise and support the vehicle. 2. Support the axle with a suitable holding fixture. 3. Remove the nuts (2), spring clamp bolts (1) and the plate that attach the spring (3) to the axle. 4. Remove the nuts (2) and bolts from the spring front and rear shackle (3). 5. Remove the spring (1) from the vehicle. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front - Independent Front Suspension > Page 13130 1. Position spring (1) on axle shaft tube so spring center bolt is inserted into the locating hole in the axle tube. 2. Align the front of the spring with the bolt hole in the front bracket. Install the eye pivot bolt and nut (4). 3. Align the rear of the spring (1) into the shackle (3) and install the bolt and nut (2). 4. Tighten the spring front and rear eye pivot bolt snug, Do not torque. 5. Install the spring clamp bolts (1), plate (3) and the retaining nuts (2). 6. Remove the holding fixture for the rear axle. 7. Remove the supports and lower the vehicle so that the weight is being supported by the tires. 8. Tighten the spring clamp retaining nuts (3) to 149 Nm (110 ft. lbs.). 9. Tighten the spring front and rear pivot bolt nuts to 163 Nm (120 ft. lbs.)(LD) or 230 Nm (170 ft. lbs.)(HD). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front - Independent Front Suspension > Page 13131 Removal REMOVAL 1. Remove the nut (1) securing the auxiliary spring bumper (2) to the bracket. 2. Remove the auxiliary spring bumper (2). Installation INSTALLATION 1. Install the auxiliary spring bumper (2). 2. Install the nut (1) securing the auxiliary spring bumper (2) to the bracket. Tighten the nut to 25 Nm (34 ft. lbs.). Removal REMOVAL 1. Raise and support the vehicle. 2. Remove both rear tire and wheel assemblies Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front - Independent Front Suspension > Page 13132 3. Position a large C-Clamp (3) adjacent to the spring clinch clip (1) and clamp the leaves of the spring together CAUTION: When working on the front leaf spring clinch clamps finish the front before starting on the rear to prevent personal injury. 4. Use an appropriate pry bar (2) to bend open the spring clinch clip (1). If necessary, remove the existing spring clinch clip isolators. 5. Use the pry bar (2) to spread apart the leaf (1). The clearance between the leaves should be enough to remove the old liner (if necessary) and install the replacement liner. 6. If necessary, remove the old spring tip liner (1). Installation INSTALLATION 1. With the prybar still inserted between the leaves, install a new spring tip liner onto the leaf. 2. Firmly seat the spring tip liner onto the leaf. A C-Clamp (1) can be used to compress the adjacent leaves together which will seat the liner retaining pin into the hole. NOTE: The spring tip liner is properly installed when the retaining pin is pointing toward the pavement and the wear pad is contacting the leaf spring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front - Independent Front Suspension > Page 13133 3. Apply a small amount of lubricant oil onto the tip liner wear pad. 4. Install all the spring tip liners. 5. Place one spring clinch clip isolator (1) onto the outboard side of the spring clinch clip and one isolator on the inboard side of the spring clinch clip. 6. Using large adjustable pliers (2), close the spring clinch clip (1) until the isolator contacts the leaf spring. CAUTION: Do not use a hammer to close the spring clinch clip. Damage to the isolator may result. 7. Use an appropriate pry bar to bend open the spring clinch clip. If necessary, remove the existing spring clinch clip isolators. 8. Repeat procedure for the other side of the vehicle. 9. Install the tire wheel assemblies. 10. Lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front - Independent Front Suspension > Page 13134 Suspension Spring ( Coil / Leaf ): Service and Repair Rear-Leaf Spring Bushings Removal REMOVAL NOTE: When removing the LD front eye bushing be sure to note the orientation of the "voids" or holes. The voids need to be in line with the main leaf when installing the new bushing or vehicle ride will degrade. 1. Remove the spring from the vehicle. 2. Make small relief cuts in the flared up end of the bushing metal being careful not to cut the spring. Use a punch to bend the flared bushing metal down for push out. 3. Position the spring eye in a press. 4. Press the bushing out with an appropriate size driver. Installation INSTALLATION NOTE: When installing the LD front eye bushing be sure to note the orientation of the "voids" or holes. The voids need to be in line with the main leaf when installing the new bushing or vehicle ride will degrade. 1. Press new bushing into the spring eye with an appropriate size driver. The bushing should be centered in the spring eye. 2. Stake the outermetal of the bushing in a minimum of six points to retain the bushing. 3. Install the spring on the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front - Independent Front Suspension Suspension Strut / Shock Absorber: Testing and Inspection Front - Independent Front Suspension DIAGNOSIS AND TESTING A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching components. These noises can usually be stopped by tightening the attaching nuts. If the noise persists, inspect for damaged and worn bushings, and attaching components. Repair as necessary if any of these conditions exist. WARNING: The shock absorbers are under high pressure. Do Not heat or attempt to open the shock absorbers. A squeal noise from the shock absorber may be caused by the hydraulic valving and may be intermittent. This condition is not repairable and the shock absorber must be replaced. A squeak or creak noise coming from the shock area may be related to any of the suspension components or mounts, but not necessarily the shock. NOTE: When inspecting the shock absorber, do not clamp the body or the piston rod. NOTE: Monotube shock absorber compression forces will be much higher than standard shock absorbers. The shock absorbers are not refillable or adjustable. If a malfunction occurs, the shock absorber must be replaced. To check a shock absorber, grasp the tube and invert the shock so the piston rod touches the ground, then compress the shock four or five times. The action throughout each stroke should be smooth and even, and the piston rod should extend from the shock on its own. The shock absorber bushings do not require any type of lubrication. Do not attempt to stop bushing noise by lubricating them. Grease and mineral oil-base lubricants will deteriorate the bushing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front - Independent Front Suspension > Page 13139 Suspension Strut / Shock Absorber: Testing and Inspection Front - Link/Coil DIAGNOSIS AND TESTING A knocking or rattling noise from a shock absorber (5) may be caused by movement between mounting grommets (1&6) and metal brackets (3) or attaching components. These noises can usually be stopped by tightening the attaching nuts. If the noise persists, inspect for damaged and worn bushings, and attaching components. Repair as necessary if any of these conditions exist. A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermittent. This condition is not repairable and the shock absorber must be replaced. The shock absorbers are not refillable or adjustable. If a malfunction occurs, the shock absorber must be replaced. To test a shock absorber, hold it in an upright position and force the piston in and out of the cylinder four or five times. The action throughout each stroke should be smooth and even. The shock absorber bushings do not require any type of lubrication. Do not attempt to stop bushing noise by lubricating them. Grease and mineral oil-base lubricants will deteriorate the bushing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front - Independent Front Suspension Suspension Strut / Shock Absorber: Service and Repair Front - Independent Front Suspension Removal 4X4-COIL OVER 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Support the lower control arm outboard end. 4. Remove the three upper shock nuts (1). 5. Remove the lower shock bolt (6) and nut. 6. Remove the caliper adapter with the caliper. 7. Remove the rotor. 8. Disconnect the wheel speed sensor wiring from the knuckle and upper control arm. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front - Independent Front Suspension > Page 13142 9. Remove the upper ball joint retaining nut and separate the upper ball joint (4) from the knuckle (6) using separator 9360 (5). 10. Remove the stabilizer link lower nut (2). 11. Remove the axle hub nut. 12. Remove the shock assembly (1). Installation 4X4-COIL OVER NOTE: All suspension components should be tighten with the weight of the vehicle on them (curb height). 1. Install the shock (1) back in place in the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front - Independent Front Suspension > Page 13143 2. Install the upper part of the shock (2) into the frame bracket (3). 3. Install the upper nuts (1). Tighten to 61 Nm (45 ft. lbs.). 4. Install the lower part of the shock (5) into the lower control arm shock bushing (7). 5. Install and position bolt (6) so head of bolt is facing rearward of vehicle and hand start nut. Tighten the bolt (6) & nut to 210 Nm (155 ft. lbs.). 6. Install the upper ball joint to the knuckle and install the retaining nut. 7. Install and tighten the axle hub nut. 8. Install the stabilizer link lower nut. 9. Reconnect the wheel speed sensor wiring to the knuckle and upper control arm. 10. Install the rotor. 11. Install the caliper adapter with the caliper. 12. Remove the support from the lower control arm outboard end. 13. Install the tire and wheel assembly. 14. Remove the support and lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front - Independent Front Suspension > Page 13144 Suspension Strut / Shock Absorber: Service and Repair Front - Link/Coil Suspension Removal REMOVAL 1. Remove the nut, retainer (4) and grommet (1) from the upper stud in the engine compartment. 2. Remove three nuts from the upper shock bracket (3). 3. Remove the lower bolt (4) from the axle bracket. Remove the shock absorber (1) from engine compartment. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front - Independent Front Suspension > Page 13145 1. Position the lower retainer (4) and grommet (6) on the upper stud. Insert the shock absorber (5) through the spring from engine compartment. 2. Install the lower bolt (4) and tighten to 135 Nm (100 ft. lbs.). 3. Install the upper shock bracket (3) and three nuts. Tighten nuts to 75 Nm (55 ft. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front - Independent Front Suspension > Page 13146 4. Install upper grommet (1) and retainer (2). Install upper shock nut and tighten to 54 Nm (40 ft. lbs). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front - Independent Front Suspension > Page 13147 Suspension Strut / Shock Absorber: Service and Repair Rear Shock Absorber Removal REMOVAL 1. Raise vehicle and support the axle. NOTE: The rear upper shock attachment uses a flag nut. Do not use an air tool to remove the bolt, the flag may rotate into the bottom of the bed and cause damage. Use a wrench to hold the nut when loosening. 2. Remove the upper shock bolt and nut (1). 3. Remove the lower shock bolt and nut. 4. Remove the rear shock absorber (3) from the vehicle. Installation INSTALLATION 1. Position the shock absorber (3) in the brackets. 2. Install the bolts through the brackets and the shock. Install the flag nut (1) on the top bolt and nut on lower bolt. 3. Tighten the upper and lower bolt/nuts. Tighten to 135 N.m (100 ft. lbs.) 4. Remove the support and lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Removal Suspension Travel Bumper: Service and Repair Removal REMOVAL 1. Remove the two bolts (1) securing the jounce bumper (2) to the bracket. 2. Remove the jounce bumper (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Removal > Page 13152 Suspension Travel Bumper: Service and Repair Installation INSTALLATION 1. Install the jounce bumper (2). 2. Install the two bolts (1) securing the jounce bumper (2) to the bracket. Tighten the bolts to 40 Nm (30 ft. lbs.)(LD) or Tighten the bolts to 61 Nm (45 ft. lbs.)(HD). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications WHEEL BEARING LUBRICANT Mopar Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front - Independent Front Suspension Wheel Bearing: Service and Repair Front - Independent Front Suspension Removal 4X4 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper and rotor. 4. Remove the ABS wheel speed sensor if equipped. 5. Remove the halfshaft nut. NOTE: Do not strike the knuckle with a hammer to remove the tie rod end or the ball joint. Damage to the steering knuckle will occur. 6. Remove the tie rod end nut and separate the tie rod from the knuckle using remover 9360. 7. Remove the upper ball joint nut and separate the upper ball joint from the knuckle using remover 9360. 8. Pull down on the steering knuckle to separate the halfshaft (2) from the hub/bearing. 9. Remove the three hub/bearing mounting bolts (1) from the steering knuckle. 10. Slide the hub/bearing out of the steering knuckle. 11. Remove the brake dust shield. Installation 4X4 1. Install the brake dust shield (2). 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts to 163 Nm (120 ft. lbs.). 3. Install the brake rotor and caliper. 4. Install the ABS wheel speed sensor if equipped. 5. Install the upper ball joint nut to the steering knuckle and tighten to 54 Nm (40 ft. lbs.) (on 1500 series only an additional 90° turn). 6. Install the tie rod end nut to the steering knuckle and tighten to 61 Nm (45 ft. lbs.) then an additional 90°. 7. Install the halfshaft nut and tighten to 251 Nm (185 ft. lbs.). 8. Install the wheel and tire assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front - Independent Front Suspension > Page 13158 9. Remove the support and lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front - Independent Front Suspension > Page 13159 Wheel Bearing: Service and Repair Front - Link/Coil Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the hub extension (1) mounting nuts and remove the extension from the rotor if equipped. 4. Remove the brake caliper. 5. Remove the cotter pin (2) and the hub nut (1) from the axle shaft. 6. Remove the caliper adapter. 7. Remove the disc brake rotor. 8. Disconnect the wheel speed sensor wire. 9. Remove the hub/bearing 4 mounting bolts and remove the hub/bearing. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front - Independent Front Suspension > Page 13160 1. Position the brake shield (1) on bolts. 2. Install the hub/bearing to the knuckle. Tighten the hub/bearing bolts (2) to 202 Nm (149 ft. lbs.) 3. Install the hub nut and tighten to 356 Nm (263 ft. lbs.). 4. Install the wheel speed sensor to the hub. 5. Install the disc brake rotor. 6. Install the brake caliper adapter with the caliper. 7. Install the hub extension and nuts to the front rotor. Tighten nuts to 130 Nm (96 ft.lbs). HD DRW ONLY. 8. Install the wheel and tire assemblies. 9. Remove the support and lower the vehicle. 10. Apply the brakes several times to seat the brake shoes and caliper piston. Do not move the vehicle until a firm brake pedal is obtained. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Hub Nut Tighten to .............................................................................................................................. ............................................................... 356 Nm (263 ft. lbs.) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation > Description Low Tire Pressure Indicator: Description and Operation Description DESCRIPTION A Tire Pressure Monitor (TPM) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional TPM, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The TPM indicator consists of a stencil-like cutout of an icon that represents a cross-section of a tire with a centered exclamation point in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The TPM indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation > Description > Page 13171 Low Tire Pressure Indicator: Description and Operation Operation OPERATION The Tire Pressure Monitor (TPM) indicator gives an indication to the vehicle operator of the status of the TPM system. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Sentry Key REmote Entry Module (SKREEM) over the Controller Area Network (CAN) data bus. The TPM indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provide a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the TPM indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position, the SKREEM sends an electronic TPM indicator lamp-ON message to the cluster to illuminate the TPM indicator for about three seconds as a bulb test. - TPM Indicator Lamp-On Message - Each time the cluster receives an electronic TPM indicator lamp-ON message from the SKREEM, the TPM indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the SKREEM message. The indicator remains illuminated until the cluster receives a lamp-OFF message from the SKREEM or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no TPM lamp-ON or lamp-OFF messages from the SKREEM for six consecutive seconds, the TPM indicator is illuminated by the instrument cluster. The indicator remains controlled and illuminated by the cluster until a valid lamp-ON or lamp-OFF message is received from the SKREEM. - Actuator Test - Each time the cluster is put through the actuator test, the TPM indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The SKREEM performs a self-test each time the ignition switch is turned to the ON position to decide whether the TPM system is in good operating condition and whether the tire inflation pressures are too high or too low. The SKREEM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the instrument cluster turns ON the TPM indicator after the bulb test, it indicates that the inflation pressure of a tire is too low or that a malfunction has occurred and the TPM system is ineffective. For proper diagnosis of the TPM system, the SKREEM, the EMIC, the CAN data bus or the electronic communication related to TPM indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Specifications Tires: Specifications TIRE REVOLUTIONS PER MILE TIRE REVOLUTIONS PER MILE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tire Tires: Description and Operation Tire TIRES Tires are designed and engineered for each specific vehicle. They provide the best overall performance for normal operation. The ride and handling characteristics match the vehicle's requirements. With proper care they will give excellent reliability, traction, skid resistance, and tread life. Driving habits have more effect on tire life than any other factor. Careful drivers will obtain in most cases, much greater mileage than severe use or careless drivers. A few of the driving habits which will shorten the life of any tire are: - Rapid acceleration - Severe brake applications - High speed driving - Excessive speeds on turns - Striking curbs and other obstacles Radial-ply tires are more prone to irregular tread wear. It is important to follow the tire rotation interval. This will help to achieve a greater tread life. TIRE IDENTIFICATION Tire type, size, aspect ratio and speed rating are encoded in the letters and numbers imprinted on the side wall of the tire. Refer to the chart to decipher the tire identification code. Performance tires have a speed rating letter after the aspect ratio number. The speed rating is not always printed on the tire sidewall. These ratings are: - Q up to 100 mph - S up to 112 mph - T up to 118 mph - U up to 124 mph - H up to 130 mph - V up to 149 mph - W (consult the tire manufacturer for the specific speed rating) - Z more than 149 mph (consult the tire manufacturer for the specific speed rating) An All Season type tire will have either M + S, M & S or M-S (indicating mud and snow traction) imprinted on the side wall. TIRE CHAINS Tire snow chains may be used on certain models. Refer to the Owner's Manual for more information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tire > Page 13177 Tires: Description and Operation Spare / Temporary Tire SPARE / TEMPORARY TIRE The temporary spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 80 KMH (50 MPH). when using the temporary spare tire. Refer to Owner's Manual for complete details. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tire > Page 13178 Tires: Description and Operation Radial - Ply Tires RADIAL - PLY TIRES Radial-ply tires improve handling, tread life and ride quality, and decrease rolling resistance. Radial-ply tires must always be used in sets of four. Under no circumstances should they be used on the front only. They may be mixed with temporary spare tires when necessary. A maximum speed of 80 KMH (50 MPH) is recommended while a temporary spare is in use. Radial-ply tires have the same load-carrying capacity as other types of tires of the same size. They also use the same recommended inflation pressures. The use of oversized tires, either in the front or rear of the vehicle, can cause vehicle drive train failure. This could also cause inaccurate wheel speed signals when the vehicle is equipped with Anti-Lock Brakes. The use of tires from different manufactures on the same vehicle is NOT recommended. The proper tire pressure should be maintained on all four tires. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tire > Page 13179 Tires: Description and Operation Replacement Tires REPLACEMENT TIRES The original equipment tires provide a proper balance of many characteristics such as: - Ride - Noise - Handling - Durability - Tread life - Traction - Rolling resistance - Speed capability It is recommended that tires equivalent to the original equipment tires be used when replacement is needed. Failure to use equivalent replacement tires may adversely affect the safety and handling of the vehicle. The use of oversize tires may cause interference with vehicle components. Under extremes of suspension and steering travel, interference with vehicle components may cause tire damage. WARNING: Failure to equip the vehicle with tires having adequate speed capability can result in sudden tire failure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tire > Page 13180 Tires: Description and Operation Full Size, Spare Wheel With Matching Tire FULL SIZE, SPARE WHEEL WITH MATCHING TIRE The spare is a full usage wheel with a matching tire, It can be used within the (posted legal) speed limits or distance limitations as of the rest of the vehicles four tires. Refer to Owner's Manual for complete details. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Pressure Gauges Tires: Testing and Inspection Pressure Gauges PRESSURE GAUGES A quality air pressure gauge is recommended to check tire pressure. After checking the air pressure, replace valve cap finger tight. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Pressure Gauges > Page 13183 Tires: Testing and Inspection Tire Noise Or Vibration TIRE NOISE OR VIBRATION Radial-ply tires are sensitive to force impulses caused by improper mounting, vibration, wheel defects, or possibly tire imbalance. To find out if tires are causing the noise or vibration, drive the vehicle over a smooth road at varying speeds. Note the noise level during acceleration and deceleration. The engine, differential and exhaust noises will change as speed varies, while the tire noise will usually remain constant. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Pressure Gauges > Page 13184 Tires: Testing and Inspection Tread Wear Indicators TREAD WEAR INDICATORS Tread wear indicators (3) are molded into the bottom of the tread grooves. When tread depth is 1.6 mm (1/16 in.), the tread wear indicators (3) will appear as a 13 mm (1/2 in.) band. Tire replacement is necessary when indicators appear in two or more grooves or if localized balding occurs. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Pressure Gauges > Page 13185 Tires: Testing and Inspection Tire Wear Patterns TIRE WEAR PATTERNS Under inflation will cause wear on the shoulders of tire. Over inflation will cause wear at the center of tire. Excessive camber causes the tire to run at an angle to the road. One side of tread is then worn more than the other. Excessive toe-in or toe-out causes wear on the tread edges and a feathered effect across the tread. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Pressure Gauges > Page 13186 Tires: Testing and Inspection Tire/Vehicle Lead TIRE/VEHICLE LEAD Use the following Vehicle Lead Diagnosis And Correction Chart to diagnose and correct a vehicle lead or drift problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures Tires: Procedures Cleaning TIRES Remove the protective coating on the tires before delivery of a vehicle. This coating may cause deterioration of the tires. To remove the protective coating, apply warm water and let it soak for a few minutes. Afterwards, scrub the coating away with a soft bristle brush. Steam cleaning may also be used to remove the coating. NOTE: DO NOT use gasoline, mineral oil, oil-based solvent or a wire brush for cleaning. Tire Inflation Pressures TIRE INFLATION PRESSURES WARNING: Over or under inflated tires can affect vehicle handling and tread wear. This may cause the tire to fail suddenly, resulting in loss of vehicle control. Under inflation will cause rapid shoulder wear (1), tire flexing, and possible tire failure. Over inflation will cause rapid center wear (1) reduction in the tire's ability to cushion shocks. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 13189 Improper inflation can cause: - Uneven wear patterns - Reduced tread life - Reduced fuel economy - Unsatisfactory ride - Vehicle drift For proper tire pressure specification refer to the vehicles Owners Manual. Tire Pressure For High Speed Operation TIRE PRESSURE FOR HIGH SPEEDS For proper tire pressure specification refer to the Owners Manual. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 13190 Tires: Removal and Replacement TIRE REPAIR AREA For proper repairing, a radial tire must be removed from the wheel. Repairs should only be made if the defect, or puncture, is in the tread area (1). The tire should be replaced if the puncture is located in the sidewall. Deflate tire completely before removing the tire from the wheel. Use lubrication such as a mild soap solution when dismounting or mounting tire. Use tools free of burrs or sharp edges which could damage the tire or wheel rim. Before mounting tire on wheel, make sure all rust is removed from the rim bead and repaint if necessary. Install wheel on vehicle, and tighten to proper torque specification. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information Wheels: Technical Service Bulletins Wheels/Tires - Chrome Clad Wheel Balancing Information NUMBER: 22-002-09 GROUP: Wheels/Tires DATE: July 29, 2009 SUBJECT: Chrome Clad Wheel Adapters For Proper Balancing OVERVIEW: This bulletin describes the use of proper wheel adapters when mounting Chrome Clad wheels to wheel balancing equipment. MODELS: 2004-2008 (CS) Pacifica 2007 - 2009 (D1) Ram Truck (3500 Pick Up) 2007 - 2010 DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2004 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2009-2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2008 - 2010 (JS27) Sebring Convertible 2007 - 2010 (JS41) Sebring/Avenger 2007-2010 (KA) Nitro 2002-2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2008 - 2010 (KK) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005-2010 (ND) Dakota 2007 - 2001 (PM) Caliber 2001 - 2009 (PT) Chrysler PT Cruiser 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2008 - 2010 (RI) Town & Country/Grand Caravan Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information > Page 13195 2008 - 2010 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005-2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander NOTE: This information applies to any model equipped with Chrome Clad Wheels. DISCUSSION: Models equipped with Chrome Clad wheels require specific piloting on balance equipment to properly center the wheel and prevent damage to the chrome clad surface. The chrome cladding is not removable or replaceable and has cladding tabs that extend into the wheel bore. Traditional high-taper cones will come into contact with the cladding tabs rather than properly seat on the hub bore chamfer. Many modern aluminum wheel designs cannot be mounted with traditional cones. Direct-Fit Collets should be used to properly mount clad wheels on balance equipment (Fig 1). SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: This kit includes the adapters for all Dodge, Chrysler & Jeep models with clad wheels. Individual adapters for specific wheel sizes can be ordered separately. To order a kit or individual adapters, contact Pentastar Service Equipment @ 1-800-223-5623. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation > Description - Wheels Wheels: Description and Operation Description - Wheels WHEELS Original equipment wheels are designed for the specified Maximum Vehicle Capacity. All models use steel or aluminum drop center wheels. Aluminum wheels require special balance weights and alignment equipment. 1. On vehicles equipped with dual rear wheels, the rim is an eight stud hole pattern wheel. The wheels have a flat mounting surface (1). 2. The slots (1) in the wheel must be aligned to provide access to the valve stem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation > Description - Wheels > Page 13198 Wheels: Description and Operation Description - Wheel Design WHEEL DESIGN The rim size is on the vehicle safety certification label located on the drivers door shut face. Original equipment wheels/rims are designed for operation up to the specified maximum vehicle capacity. All models use stamped steel, cast aluminum or forged aluminum wheels. Every wheel has raised sections between the rim flanges (1) and rim drop well (3) called safety humps. Initial inflation of the tire forces the bead over these raised sections. In case of rapid loss of air pressure, the raised sections help hold the tire on the wheel. The wheel studs and nuts are designed for specific applications. All aluminum and some steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Do not use replacement studs or nuts with a different design or lesser quality. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 13199 Wheels: Testing and Inspection WHEEL INSPECTION Inspect wheels for: - Excessive runout - Dents, cracks or irregular bends - Damaged wheel stud (lug) holes - Air Leaks NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged, an original equipment replacement wheel should be used. When obtaining replacement wheels, they must be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: Failure to use equivalent replacement wheels may adversely affect the safety and handling of the vehicle. WARNING: Replacement with used wheels is not recommended. The service history of the wheel may have included severe treatment or very high mileage. The rim could fail without warning. WARNING: DaimlerChrysler Corporation does not recommend that customers use "reconditioned" wheels (wheels that have been damaged and repaired) because they can result in a sudden catastrophic wheel failure which could cause loss of control and result in injury or death. For clarification: - Cosmetic refinishing for the purpose of repairing a superficial flaw is an acceptable procedure providing it is limited to paint or clear coat only, the wheel is not modified in any way, and there is no exposure to paint curing heat over 200 degrees Fahrenheit. - Damaged wheels are those which have been bent, broken, cracked or sustained some other physical damage which may have compromised the wheel structure. - Repaired indicates that the wheel has been modified through bending, welding, heating, straightening, or material removal to rectify damage. - Re-plating of chrome plated wheels is not an acceptable procedure nor is chrome plating of original equipment painted or polished wheels, as this may alter mechanical properties and affect fatigue life. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications WHEEL BEARING LUBRICANT Mopar Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front - Independent Front Suspension Wheel Bearing: Service and Repair Front - Independent Front Suspension Removal 4X4 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper and rotor. 4. Remove the ABS wheel speed sensor if equipped. 5. Remove the halfshaft nut. NOTE: Do not strike the knuckle with a hammer to remove the tie rod end or the ball joint. Damage to the steering knuckle will occur. 6. Remove the tie rod end nut and separate the tie rod from the knuckle using remover 9360. 7. Remove the upper ball joint nut and separate the upper ball joint from the knuckle using remover 9360. 8. Pull down on the steering knuckle to separate the halfshaft (2) from the hub/bearing. 9. Remove the three hub/bearing mounting bolts (1) from the steering knuckle. 10. Slide the hub/bearing out of the steering knuckle. 11. Remove the brake dust shield. Installation 4X4 1. Install the brake dust shield (2). 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts to 163 Nm (120 ft. lbs.). 3. Install the brake rotor and caliper. 4. Install the ABS wheel speed sensor if equipped. 5. Install the upper ball joint nut to the steering knuckle and tighten to 54 Nm (40 ft. lbs.) (on 1500 series only an additional 90° turn). 6. Install the tie rod end nut to the steering knuckle and tighten to 61 Nm (45 ft. lbs.) then an additional 90°. 7. Install the halfshaft nut and tighten to 251 Nm (185 ft. lbs.). 8. Install the wheel and tire assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front - Independent Front Suspension > Page 13205 9. Remove the support and lower vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front - Independent Front Suspension > Page 13206 Wheel Bearing: Service and Repair Front - Link/Coil Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the hub extension (1) mounting nuts and remove the extension from the rotor if equipped. 4. Remove the brake caliper. 5. Remove the cotter pin (2) and the hub nut (1) from the axle shaft. 6. Remove the caliper adapter. 7. Remove the disc brake rotor. 8. Disconnect the wheel speed sensor wire. 9. Remove the hub/bearing 4 mounting bolts and remove the hub/bearing. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front - Independent Front Suspension > Page 13207 1. Position the brake shield (1) on bolts. 2. Install the hub/bearing to the knuckle. Tighten the hub/bearing bolts (2) to 202 Nm (149 ft. lbs.) 3. Install the hub nut and tighten to 356 Nm (263 ft. lbs.). 4. Install the wheel speed sensor to the hub. 5. Install the disc brake rotor. 6. Install the brake caliper adapter with the caliper. 7. Install the hub extension and nuts to the front rotor. Tighten nuts to 130 Nm (96 ft.lbs). HD DRW ONLY. 8. Install the wheel and tire assemblies. 9. Remove the support and lower the vehicle. 10. Apply the brakes several times to seat the brake shoes and caliper piston. Do not move the vehicle until a firm brake pedal is obtained. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Removal Wheel Cover: Service and Repair Removal REMOVAL NOTE: The hub caps must be removed before raising the vehicle off the ground. NOTE: You must use the flat end of the hub/cap remover/installer combination tool to pry off the wheel skins. Insert the flat tip completely and using a back and forth motion, loosen the wheel skin. repeat this procedure around the tire until the wheel skin pops off. 1. On 2500/3500 single rear wheel (SRW) models, insert a hub/cap remover/installer combination tool using the blade on the end of the tool to pry the cap off in a back and forth motion. 2. On 3500 models with dual rear wheels (DRW), you must first remove the hub caps. The hub/cap remover/installer combination tool must be inserted in the pry off notch of the rear hub caps. 3. Position the hub/cap remover/installer combination tool and pull out on the tool firmly. The cap should come off. NOTE: Failure to use a back and forth motion could damage the wheel skin chrome finish. 4. The wheel skins can now be removed from the wheel. Use the flat end of the lug nut wrench to pry off the wheel skins. Make sure that the flat end is inserted and use a back and forth motion to remove the wheel skin. 5. On 3500 models front hub caps use the hub/cap remover/installer combination tool to pry off the cap in a back and forth motion. The wheel skins can now be removed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Removal > Page 13212 Wheel Cover: Service and Repair Installation Front FRONT 1. Align the valve stem with the notch in the wheel skin. 2. Seat on side of the wheel skin's wire retainer on to the wheel. 3. Using a rubber mallet, strike the opposite side of the wheel skin until the skin is properly seated. NOTE: The wheel skin and the hub cap are fully seated when there is a consistant gap between the skin/ cap and the wheel. 4. Tug on the hub cap/wheel skin to ensure that they are properly installed. Rear REAR 1. Install one 1 1/2 in. valve stem extension on each rear inner wheel. NOTE: A 3/8 in. drive 10mm deep wheel socket with a 10 in. or greater extension can be used to remove the existing valve stem cap and install the extension. 2. Install one 1 in. valve stem extension on each outer wheel. 3. Align the cooling windows of the wheel skin with the cooling windows of the wheel. Seat one side of the wheel skin's retainer onto the wheel. Using a rubber mallet, strike thew wheel skin on the outer circumference. Strike at several locations around the circumference until the skin is fully seated. NOTE: The wheel skin and the hub cap are fully seated when there is a consistent gap between the skin/cap and the wheel. 4. Tug on the hub/cap wheel skin to ensure that they are properly installed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Hub Nut Tighten to .............................................................................................................................. ............................................................... 356 Nm (263 ft. lbs.) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications TORQUE Torque Specifications Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Removal Wheel Fastener: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, caliper adapter and rotor. 4. Remove the wheel speed sensor from the hub. 5. Press the stud from the hub using remover C-4150A (1). 6. Remove the stud (2) from the hub (1) through the backing plate access hole (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Removal > Page 13222 Wheel Fastener: Service and Repair Installation INSTALLATION 1. Install the new stud (2) into the hub flange (1). 2. Install three proper sized washers onto the stud, then install lug nut with the flat side of the nut against the washers. 3. Tighten the lug nut until the stud is pulled into the hub flange. Verify that the stud is properly seated into the flange. 4. Remove the lug nut and washers. 5. Install the brake rotor, caliper adapter, and caliper. 6. Install the wheel speed sensor. 7. Install the wheel and tire assembly, use new lug nut on the stud or studs that were replaced. 8. Remove the support and lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and Operation > Description Accumulator HVAC: Description and Operation Description DESCRIPTION To protect the A/C compressor from any liquid slugging, an A/C accumulator (5) is used in this A/C system to retain any refrigerant that may exit from the evaporator in a liquid state. The A/C accumulator is mounted in the engine compartment between the evaporator outlet tube (2) and the A/C suction line (6). An integral mounting bracket (4) is used to secure the accumulator to the dash panel (3). The A/C low side service port (1) is mounted to the top of the A/C accumulator. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and Operation > Description > Page 13228 Accumulator HVAC: Description and Operation Operation OPERATION Refrigerant enters the A/C accumulator (1) mostly as a low pressure vapor through the inlet tube (2). Any liquid, oil-laden refrigerant falls to the bottom of the canister, which acts as a separator. A desiccant bag (3) is mounted inside the accumulator canister to absorb any moisture which may have entered and become trapped within the refrigerant system. A filter (4) is also mounted inside the canister to trap any foreign material that may have entered the refrigerant system during assembly. The low pressure vapor exits the A/C accumulator through the outlet tube (5). On this model, the low side service port (6) is located at the top of the A/C accumulator. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C accumulator has no serviceable parts except for the rubber O-ring seals, low side service port valve, cap and secondary retaining clips. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C accumulator is removed and installed. The A/C accumulator cannot be repaired and must be replaced if found to be leaking or damaged, or if an internal failure of the A/C compressor has occurred. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Removal Accumulator HVAC: Service and Repair Removal REMOVAL WARNING: Review the warnings and cautions before performing the following operation. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system. 3. Remove the air filter housing cover to gain access to the A/C accumulator (9). 4. Remove the secondary retaining clip (11) from the spring-lock coupler (1) that secures the A/C suction line (10) to the accumulator outlet tube (2). 5. Using the proper A/C line disconnect tool (Special Tool Kit 7193 or equivalent), disconnect the A/C suction line from the A/C accumulator and remove and discard the O-ring seals. 6. If equipped, disengage the push-pin type wire harness retainer from the plastic wire harness bracket located on the side of the A/C accumulator and position the engine wire harness out of the way. 7. Loosen the bolts (8) that secure the A/C accumulator to the bracket (7) located on the dash panel. 8. Remove the secondary retaining clip (4) from the spring-lock coupler (6) that secures the accumulator inlet tube (3) to the evaporator outlet tube (5). 9. Using the proper A/C line disconnect tool (Special Tool Kit 7193 or equivalent), disconnect the accumulator inlet tube from the evaporator outlet tube and remove and discard the O-ring seals. 10. Install plugs in, or tape over the opened refrigerant system connections. 11. If the A/C accumulator is being replaced, remove the accumulator mounting bolts and the plastic wire harness bracket (if equipped) from the accumulator. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Removal > Page 13231 Accumulator HVAC: Service and Repair Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: The A/C accumulator must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C accumulator can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. NOTE: If only the A/C accumulator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only the refrigerant oil of the type recommended for the A/C compressor in the vehicle. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. 1. If the A/C accumulator (9) is being replaced, loosely install the accumulator mounting bolts (8) and the plastic wire harness bracket (if equipped) on to the accumulator. 2. Position the A/C accumulator onto the bracket located on the dash panel (7) in the engine compartment. Do not tighten the accumulator mounting bolts at this time. 3. Remove the tape or plugs from the opened refrigerant system connections. 4. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the accumulator tube fittings (1 and 6). Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Connect the spring-lock coupler that secures the accumulator inlet tube (3) to the evaporator outlet tube (5) and install the secondary retaining clip (4). 6. Tighten the accumulator mounting bolts to 6.8 Nm (60 in. lbs.). 7. If equipped, engage the engine wire harness retaining clip to the plastic wire harness bracket located on the side of the A/C accumulator. 8. Connect the A/C suction line (10) to the accumulator outlet tube (2) and install the secondary retaining clip (11). 9. Install the air filter housing cover. 10. Reconnect the battery negative cable. 11. Evacuate the refrigerant system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Removal > Page 13232 12. If the A/C accumulator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 13. Charge the refrigerant system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Actuator-Blend Door-Driver Air Door Actuator / Motor: Locations Actuator-Blend Door-Driver Component ID: 1 Component : ACTUATOR-BLEND DOOR-DRIVER Connector: Name : ACTUATOR-BLEND DOOR-DRIVER Color : GRAY # of pins : 2 Pin Description Circuit 1 COMMON DOOR DRIVER C34 20DB/LB 2 BLEND DOOR DRIVER C61 20DB/LG Component Location - 40 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Actuator-Blend Door-Driver > Page 13238 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Actuator-Blend Door-Driver > Page 13239 Air Door Actuator / Motor: Locations Actuator-Blend Door-Passenger Component ID: 2 Component : ACTUATOR-BLEND DOOR-PASSENGER Connector: Name : ACTUATOR-BLEND DOOR-PASSENGER Color : GRAY # of pins : 2 Qualifier : (DUAL ZONE) Pin Description Circuit 1 COMMON DOOR DRIVER C34 20DB/LB 2 PASSENGER BLEND DOOR DRIVER C33 20LB/BR Component Location - 40 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Actuator-Blend Door-Driver > Page 13240 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Actuator-Blend Door-Driver > Page 13241 Air Door Actuator / Motor: Locations Actuator-Mode Door 1 Component ID: 5 Component : ACTUATOR-MODE DOOR 1 Connector: Name : ACTUATOR-MODE DOOR 1 Color : GRAY # of pins : 2 Qualifier : (PANEL TO FLOOR) Pin Description Circuit 1 COMMON DOOR DRIVER C34 20DB/LB 2 MODE DOOR 1 DRIVER C801 20DB/OR Component Location - 40 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Actuator-Blend Door-Driver > Page 13242 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Actuator-Blend Door-Driver > Page 13243 Air Door Actuator / Motor: Locations Actuator-Mode Door 2 Component ID: 6 Component : ACTUATOR-MODE DOOR 2 Connector: Name : ACTUATOR-MODE DOOR 2 Color : GRAY # of pins : 2 Qualifier : (DEFROST TO FLOOR) Pin Description Circuit 1 COMMON DOOR DRIVER C34 20DB/LB 2 MODE DOOR 2 DRIVER C29 20DB/OR Component Location - 40 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Actuator-Blend Door-Driver > Page 13244 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Actuator-Blend Door-Driver Air Door Actuator / Motor: Diagrams Actuator-Blend Door-Driver Component ID: 1 Component : ACTUATOR-BLEND DOOR-DRIVER Connector: Name : ACTUATOR-BLEND DOOR-DRIVER Color : GRAY # of pins : 2 Pin Description Circuit 1 COMMON DOOR DRIVER C34 20DB/LB 2 BLEND DOOR DRIVER C61 20DB/LG Component Location - 40 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Actuator-Blend Door-Driver > Page 13247 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Actuator-Blend Door-Driver > Page 13248 Air Door Actuator / Motor: Diagrams Actuator-Blend Door-Passenger Component ID: 2 Component : ACTUATOR-BLEND DOOR-PASSENGER Connector: Name : ACTUATOR-BLEND DOOR-PASSENGER Color : GRAY # of pins : 2 Qualifier : (DUAL ZONE) Pin Description Circuit 1 COMMON DOOR DRIVER C34 20DB/LB 2 PASSENGER BLEND DOOR DRIVER C33 20LB/BR Component Location - 40 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Actuator-Blend Door-Driver > Page 13249 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Actuator-Blend Door-Driver > Page 13250 Air Door Actuator / Motor: Diagrams Actuator-Mode Door 1 Component ID: 5 Component : ACTUATOR-MODE DOOR 1 Connector: Name : ACTUATOR-MODE DOOR 1 Color : GRAY # of pins : 2 Qualifier : (PANEL TO FLOOR) Pin Description Circuit 1 COMMON DOOR DRIVER C34 20DB/LB 2 MODE DOOR 1 DRIVER C801 20DB/OR Component Location - 40 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Actuator-Blend Door-Driver > Page 13251 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Actuator-Blend Door-Driver > Page 13252 Air Door Actuator / Motor: Diagrams Actuator-Mode Door 2 Component ID: 6 Component : ACTUATOR-MODE DOOR 2 Connector: Name : ACTUATOR-MODE DOOR 2 Color : GRAY # of pins : 2 Qualifier : (DEFROST TO FLOOR) Pin Description Circuit 1 COMMON DOOR DRIVER C34 20DB/LB 2 MODE DOOR 2 DRIVER C29 20DB/OR Component Location - 40 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Actuator-Blend Door-Driver > Page 13253 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Actuator-Blend Door-Driver > Page 13254 Air Door Actuator / Motor: Diagrams Actuator-Recirculation Door Component ID: 7 Component : ACTUATOR-RECIRCULATION DOOR Connector: Name : ACTUATOR-RECIRCULATION DOOR Color : GRAY # of pins : 2 Pin Description Circuit 1 COMMON DOOR DRIVER C34 20DB/LB 2 RECIRCULATION DOOR DRIVER C32 20DB/TN Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator Air Door Actuator / Motor: Description and Operation Blend Door Actuator Description DESCRIPTION The blend door actuators are reversible, 12-volt direct current (DC), servo motors. Models with the single zone heating-A/C system have a single blend-air door, which is controlled by a single blend door actuator. Models with the dual zone system have two blend-air doors, which are controlled by two blend door actuators. The blend door actuator (1) for the single zone heating-A/C system is located near the center of the HVAC housing (2), close to the dash panel. For the dual zone heating-A/C system, the same blend door actuator used for the single zone system becomes the driver side blend door actuator, which is mechanically connected to only the driver side blend-air door. A second separate blend door actuator (3) located on the top of the HVAC housing is mechanically connected to the passenger side blend-air door. All actuators (1) are interchangeable with each other. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle (2). Each actuator also has an identical output shaft with splines (3) that connect it to its respective door linkage and three integral mounting tabs (4) that allow the actuator to be secured to the HVAC housing. The blend door actuators do not require mechanical indexing to the blend-air doors, as they are electronically calibrated by the A/C-heater control. Operation OPERATION The blend door actuators are connected to the A/C-heater control through the vehicle electrical system by a dedicated two-wire lead and connector of the Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator > Page 13257 HVAC wire harness. The blend door actuator(s) can move the blend-air door(s) in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the blend-air door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the blend-air door moves in the opposite direction. When the A/C-heater control makes the voltage to both connections high or both connections low, the blend-air door stops and will not move. The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the blend door actuator(s) and the blend-air door(s). The A/C-heater control learns the blend-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the blend door actuator circuits. The blend door actuators are diagnosed using a scan tool. The blend door actuators cannot be adjusted or repaired and must be replaced if found inoperative or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator > Page 13258 Air Door Actuator / Motor: Description and Operation Mode Door Actuator Description DESCRIPTION The mode door actuators are reversible, 12-volt direct current (DC) servo motors. The heating-A/C systems on this vehicle use two mode door actuators. One for the panel/floor-air door and one for the defrost-air door. Both the defrost door actuator (1) and the panel/floor door actuator (2) and the are located on the driver side end of the HVAC housing (3), close to the dash panel. All actuators (1) are interchangeable with each other. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle (2). Each actuator also has an identical output shaft with splines (3) that connects it to its respective door linkage and three integral mounting tabs (4) that allow the actuator to be secured to the HVAC housing. The mode door actuators do not require mechanical indexing to the mode- air doors, as they are electronically calibrated by the A/C-heater control. Operation OPERATION The mode door actuators are connected to the A/C-heater control through the vehicle electrical system by dedicated two-wire leads and connectors of the HVAC wire harness. The mode door actuators can move the defrost-air door and the panel/floor-air door in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the mode-air door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the mode-air door moves in the opposite direction. When the A/C-heater control makes the voltage to both connections high or both connections low, the mode-air door stops and will not move. The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the mode door actuators and the mode-air doors. The A/C-heater control learns the mode-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator > Page 13259 for any problems it detects in the mode door actuator circuits. The mode door actuators are diagnosed using using a scan tool. The mode door actuators cannot be adjusted or repaired and must be replaced if found inoperative or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator > Page 13260 Air Door Actuator / Motor: Description and Operation Recirculation Door Actuator Description DESCRIPTION The recirculation door actuator (1) is a reversible 12-volt direct current (DC) servo motor. The single recirculation door actuator is located on the passenger side end of the HVAC housing (2), on the top of the air inlet housing. All actuators (1) are interchangeable with each other. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle (2). Each actuator also has an identical output shaft with splines (3) that connects it to its respective door linkage and three integral mounting tabs (4) that allow the actuator to be secured to the HVAC housing. The recirculation door actuator does not require mechanical indexing to the recirculation-air door, as it is electronically calibrated by the A/C-heater control. Operation OPERATION The recirculation door actuator is connected to the heater-A/C control module through the vehicle electrical system by a dedicated two-wire lead and connector of the HVAC wire harness. The recirculation door actuator can move the recirculation-air door in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the recirculation-air door will move in one direction. When the A/C-heater control makes the voltage to both connections high or both connections low, the recirculation-air door stops and will not move. The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the recirculation door actuator and the recirculation-air door. The A/C-heater control learns the recirculation-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the recirculation door actuator circuits. The recirculation door actuator is diagnosed using a scan tool. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator > Page 13261 The recirculation door actuator cannot be adjusted or repaired and must be replaced if found inoperative or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Air Door Actuator / Motor: Service and Repair Blend Door Actuator Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. NOTE: The single zone heating-A/C system is equipped with a single blend door actuator. The dual zone system has two blend door actuators, one for the driver side blend-air door and one for the passenger side blend-air door. SINGLE ZONE/DUAL ZONE DRIVER SIDE 1. Disconnect and isolate the negative battery cable. 2. Remove the instrument panel from the vehicle. 3. Remove the two screws (1) that secure the blend door actuator (2) to the back of the HVAC housing (3). 4. Remove the blend door actuator from the HVAC housing and disconnect the HVAC wire harness connector (4) from the actuator. 5. Remove the blend door actuator from the vehicle. DUAL ZONE PASSENGER SIDE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator > Page 13264 6. Disconnect and isolate the negative battery cable. 7. Remove the instrument panel from the vehicle. 8. Remove the blend door lever (1) from the blend door actuator output shaft (2) and the blend door linkage (3). 9. Remove the two screws (1) that secure the blend door actuator and bracket assembly (2) to the top of the HVAC housing (3). 10. Remove the blend door actuator and bracket assembly from the HVAC housing and disconnect the HVAC wire harness connector (4) from the actuator. 11. Remove the blend door actuator and bracket assembly from the vehicle. Installation INSTALLATION NOTE: The single zone heating-A/C system is equipped with a single blend door actuator. The dual zone system has two blend door actuators, one for the driver side blend-air door and one for the passenger side blend-air door. SINGLE ZONE/DUAL ZONE DRIVER SIDE 1. Install the blend door actuator (1) onto the back of the HVAC housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those on the blend door lever (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator > Page 13265 2. Install the screws (1) that secure the blend door actuator (2) to the HVAC housing (3). Tighten the screws to 1.1 Nm (10 in. lbs.). 3. Connect the HVAC wire harness connector (4) to the blend door actuator. 4. Install the instrument panel. 5. Reconnect the negative battery cable. DUAL ZONE PASSENGER SIDE 6. Install the blend door actuator and bracket assembly (2) onto the top of the HVAC housing (3). 7. Install the screws (1) that secure the blend door actuator and bracket assembly to the HVAC housing. Tighten the screws to 1.1 Nm (10 in. lbs.). 8. Connect the HVAC wire harness connector (4) to the blend door actuator. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator > Page 13266 NOTE: Align the guide pin on the blend door lever with the guides on the blend door linkage during installation of the blend door lever. 9. Install the blend door lever (1) onto the blend door actuator output shaft (2) and the blend door linkage (3). 10. Install the instrument panel. 11. Reconnect the negative battery cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator > Page 13267 Air Door Actuator / Motor: Service and Repair Mode Door Actuator Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in an accidental airbag deployment and possible personal injury or death. NOTE: The heating-A/C system is equipped with two mode door actuators, one for the panel/floor-air door and one for the defrost-air door. PANEL/FLOOR DOOR ACTUATOR 1. Disconnect and isolate the negative battery cable. 2. Remove the instrument panel from the vehicle. 3. Remove the screws (1) that secure the panel/floor door actuator (2) to the back of the HVAC housing (3). 4. Remove the panel/floor door actuator from the HVAC housing and disconnect the HVAC wire harness connector (4) from the actuator. 5. Remove the panel/floor door actuator from the vehicle. DEFROST DOOR ACTUATOR 6. Disconnect and isolate the negative battery cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator > Page 13268 7. Remove the instrument panel from the vehicle. 8. Remove the screws (1) that secure the defrost door actuator (2) to the back of the HVAC housing (3). 9. Remove the defrost door actuator from the HVAC housing and disconnect the HVAC wire harness connector (4) from the actuator. 10. Remove the defrost door actuator from the vehicle. Installation INSTALLATION NOTE: The heating-A/C system is equipped with two mode door actuators, one for the panel/floor-air door and one for the defrost-air door. PANEL/FLOOR DOOR ACTUATOR 1. Install the panel/floor door actuator (1) onto the back of the HVAC housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those on the panel/floor door actuator coupler (4). 2. Install the screws (1) that secure the panel/floor door actuator (2) to the HVAC housing (3). Tighten the screws to 1.1 Nm (10 in. lbs.). 3. Connect the HVAC wire harness connector (4) to the panel/floor door actuator. 4. Install the instrument panel. 5. Reconnect the negative battery cable. DEFROST DOOR ACTUATOR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator > Page 13269 6. Install the defrost door actuator (1) onto the back of the HVAC housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those on the defrost door actuator coupler (4). 7. Install the screws (1) that secure the defrost door actuator (2) to the HVAC housing (3). Tighten the screws to 1.1 Nm (10 in. lbs.). 8. Connect the HVAC wire harness connector (4) to the defrost door actuator. 9. Install the instrument panel. 10. Reconnect the negative battery cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator > Page 13270 Air Door Actuator / Motor: Service and Repair Recirculation Door Actuator Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. 1. Disconnect and isolate the negative battery cable. 2. Remove the glove box from the instrument panel. 3. Remove the two screws (1) that secure the recirculation door actuator (2) to the side of the HVAC air inlet housing (3). 4. Remove the recirculation door actuator from the air inlet housing and disconnect the HVAC wire harness connector (4) from the actuator. 5. Remove the recirculation door actuator from the vehicle. Installation INSTALLATION 1. Install the recirculation door actuator (1) onto the side of the HVAC air inlet housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those in the recirculation door actuator coupler (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator > Page 13271 2. Install the two screws (1) that secure the recirculation door actuator (2) to the air inlet housing (3). Tighten the screws to 1.1 Nm (10 in. lbs.). 3. Connect the HVAC wire harness connector (4) to the recirculation door actuator. 4. Install the glove box. 5. Reconnect the negative battery cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Description and Operation Air Duct: Description and Operation DESCRIPTION There are four defroster air outlets (1) in the defroster grille (2) located on the top of the instrument panel (3). The airflow from the defroster outlets is directed by fixed vanes in the defroster grille and cannot be adjusted. The defroster air outlets are not serviceable from the defroster grille. There are two side window demister air outlets (4). One located on each end of the instrument panel near the A-pillar area. The airflow from the side window demister air outlets is directed by fixed vanes in the outlets and cannot be adjusted. The driver side window demister air outlet is serviced with the instrument cluster bezel and the passenger side demister outlet is serviced with the passenger side instrument panel air outlet. There are four instrument panel air outlets (5). One air outlet is located near the end of the instrument panel facing the rear of the vehicle and two outlets are located on the instrument panel center bezel. Each of the instrument panel air outlets contain a grille with movable vanes that are used to direct or shut off the flow of the conditioned air leaving the instrument panel outlets. The driver side instrument panel air outlet is serviced with the instrument cluster bezel. The passenger side instrument panel air outlet is serviced separately from the instrument panel cover and the two center air outlets are serviced with the center bezel. On Mega Cab models there are two outlets (1) located at the rear of the center front seat support (2). Each of the rear air outlets contain a grille with movable vanes that are used to direct or shut off the flow of the conditioned air leaving the outlets. The rear air outlets are serviced as an assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console Air Duct: Service and Repair Duct-Floor Console Removal REMOVAL NOTE: Illustration shown with seat cushions removed for clarity. 1. Remove the floor console. 2. Disengage the floor console duct (1) from the rear duct adapter (3) located at the front of the rear duct (2) below the center front seat and slide the adapter rearward into the rear duct. 3. Disengage the floor console duct from the floor distribution duct (4) located on the bottom of the HVAC housing (5) and remove the console duct from the vehicle. NOTE: Illustration shown with center front seat removed for clarity. 4. If required, remove the front seat and remove the three push-pin retainers (1) that secure the rear duct (2) to the bottom of the center seat support (3). 5. Disengage the rear duct from the rear outlet (4) and remove the rear duct. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 13277 NOTE: Illustration shown with center front seat removed for clarity. 1. If removed, install the rear duct (2) onto the rear outlet (4). Make sure the duct is fully engaged to the outlet. 2. Install the three push-pin retainers (1) that secure the rear duct to the front seat support (3) and install the front seat. NOTE: Illustration shown with seat cushions removed for clarity. 3. Install the floor console duct (1) onto the floor distribution duct (4) located at the bottom of the HVAC housing (5). Make sure the ducts are fully engaged to each other. 4. Slide the rear duct adapter (3) forward and install the floor console duct onto the rear duct (2). Make sure the ducts are fully engaged to each other. 5. Install the floor console. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 13278 Air Duct: Service and Repair Outlets-Air Removal-Front Passenger Air Outlet REMOVAL-FRONT PASSENGER AIR OUTLET WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in an accidental airbag deployment and possible personal injury or death. NOTE: Take the proper precautions to protect the instrument panel from cosmetic damage. 1. Remove the instrument panel and place it on a workbench. 2. Remove the instrument panel cover from the instrument panel support. CAUTION: Use care when removing the heads from the heat stakes located on the back of the instrument panel cover. Remove only enough material from the heat stakes to allow removal of the instrument panel air outlet and demister air outlet assembly from the cover. 3. Using an 11 mm (7/16 in.) drill bit, carefully remove the heads from the six heat stakes (1) that secure the passenger side air outlet and demister air outlet assembly (2) to the back of the instrument panel cover (3). CAUTION: Use care when removing the air outlet assembly from the instrument panel cover to prevent damage to the remaining portion of the heat stakes. 4. Carefully remove the air outlet assembly from the instrument panel cover. Removal-Rear Seat Air Outlets REMOVAL-REAR SEAT AIR OUTLETS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 13279 NOTE: Illustration shown with front seat cushions removed for clarity. 1. Remove the two screws (1) that secure the rear air outlet housing (2) to the rear of the front center seat support (3). 2. Remove the rear air outlet housing and place it on a workbench. 3. Using a trim stick C-4755 or equivalent (1), disengage the retaining tabs that secure the rear air outlets (2) to the rear air outlet housing (3) and gently pry the outlets from the housing (3). Installation-Front Passenger Air Outlet INSTALLATION-FRONT PASSENGER AIR OUTLET 1. Position the passenger side instrument panel air outlet and demister air outlet assembly (2) onto the back of the instrument panel cover (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 13280 CAUTION: Always use the retaining screws supplied with the replacement air outlet. Do not use screws longer then 10 mm. Failure to follow this caution may result in damage to the instrument panel cover. CAUTION: Use care when installing the air outlet retaining screws. To prevent damage to the instrument panel cover, do not overtighten the screws. 2. Install six M 4.2 x 9.5 mm screws (1) to secure the air outlet assembly to the instrument panel cover. Carefully tighten the screws securely. 3. Install the instrument panel cover. 4. Install the instrument panel. Installation-Rear Seat Air Outlets INSTALLATION-REAR SEAT AIR OUTLETS NOTE: The air outlets are retained into the air outlet housing by eight retaining tabs. The air outlets must be first installed onto the bottom set of retaining tabs, then the upper set of tabs can be engaged. 1. Position the rear air outlets (1) to the back of the rear air outlet housing (2) and engage the lower set of retaining tabs (3). 2. Gently engage the upper set of retaining tabs (4). Make sure all of the retaining tabs are fully seated. NOTE: Illustration shown with front seat cushions removed for clarity. 3. Position the rear air outlet housing (2) to the rear of the front center seat support (3). 4. Install the two screws (1) that secure the rear air outlet housing to the center seat support. Tighten the screws to 2.2 Nm (20 in. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 13281 Air Duct: Service and Repair Defroster Duct Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. NOTE: Take the proper precautions to protect the instrument panel from cosmetic damage. 1. Remove the instrument panel and place it on a workbench. 2. If required, disconnect the center radio speaker wire harness connector (1) and position it the wire harness lead out of the way. 3. Remove the screw (4) that secures the defroster duct adapter (3) to the instrument panel support. 4. Remove the defroster duct adapter from the defroster duct (5). 5. Remove the six screws (2) that secure the defroster duct to the instrument panel. 6. Remove the defroster duct from the instrument panel. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 13282 1. Position the defroster duct (5) into the instrument panel. 2. Install the six screws (2) that secure the defroster duct to the instrument panel. Tighten the screws to 2.2 Nm (20 in. lbs.). 3. Install the defroster duct adapter (3) onto the defroster duct. 4. Install the screw (4) that secures the defroster duct adapter to the instrument panel support. Tighten the screw to 2.2 Nm (20 in. lbs.). 5. If removed, connect the center radio speaker wire harness connector (1) to the speaker. 6. Install the instrument panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 13283 Air Duct: Service and Repair Duct-Floor Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in an accidental airbag deployment and possible personal injury or death. NOTE: Regular Cab model shown. Other models similar. 1. Remove the HVAC housing from the vehicle. 2. Remove the screws (3) that secure the floor distribution duct (1) to the bottom of the HVAC housing (2). 3. Remove the floor distribution duct from the HVAC housing. Installation INSTALLATION NOTE: Regular Cab model shown. Other models similar. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 13284 1. Position the floor distribution duct (1) onto the bottom of the HVAC housing (2). 2. Install the screws (3) that secure the floor distribution duct to the HVAC housing. Tighten the screws to 1.1 Nm (10 in. lbs.). 3. Install the HVAC housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 13285 Air Duct: Service and Repair Removal REMOVAL NOTE: Illustration shown with seat cushions removed for clarity. 1. Remove the floor console. 2. Disengage the floor console duct (1) from the rear duct adapter (3) located at the front of the rear duct (2) below the center front seat and slide the adapter rearward into the rear duct. 3. Disengage the floor console duct from the floor distribution duct (4) located on the bottom of the HVAC housing (5) and remove the console duct from the vehicle. NOTE: Illustration shown with center front seat removed for clarity. 4. If required, remove the front seat and remove the three push-pin retainers (1) that secure the rear duct (2) to the bottom of the center seat support (3). 5. Disengage the rear duct from the rear outlet (4) and remove the rear duct. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 13286 NOTE: Illustration shown with center front seat removed for clarity. 1. If removed, install the rear duct (2) onto the rear outlet (4). Make sure the duct is fully engaged to the outlet. 2. Install the three push-pin retainers (1) that secure the rear duct to the front seat support (3) and install the front seat. NOTE: Illustration shown with seat cushions removed for clarity. 3. Install the floor console duct (1) onto the floor distribution duct (4) located at the bottom of the HVAC housing (5). Make sure the ducts are fully engaged to each other. 4. Slide the rear duct adapter (3) forward and install the floor console duct onto the rear duct (2). Make sure the ducts are fully engaged to each other. 5. Install the floor console. Removal-Front Passenger Air Outlet REMOVAL-FRONT PASSENGER AIR OUTLET WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in an accidental airbag deployment and possible personal injury or death. NOTE: Take the proper precautions to protect the instrument panel from cosmetic damage. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 13287 1. Remove the instrument panel and place it on a workbench. 2. Remove the instrument panel cover from the instrument panel support. CAUTION: Use care when removing the heads from the heat stakes located on the back of the instrument panel cover. Remove only enough material from the heat stakes to allow removal of the instrument panel air outlet and demister air outlet assembly from the cover. 3. Using an 11 mm (7/16 in.) drill bit, carefully remove the heads from the six heat stakes (1) that secure the passenger side air outlet and demister air outlet assembly (2) to the back of the instrument panel cover (3). CAUTION: Use care when removing the air outlet assembly from the instrument panel cover to prevent damage to the remaining portion of the heat stakes. 4. Carefully remove the air outlet assembly from the instrument panel cover. Removal-Rear Seat Air Outlets REMOVAL-REAR SEAT AIR OUTLETS NOTE: Illustration shown with front seat cushions removed for clarity. 1. Remove the two screws (1) that secure the rear air outlet housing (2) to the rear of the front center seat support (3). 2. Remove the rear air outlet housing and place it on a workbench. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 13288 3. Using a trim stick C-4755 or equivalent (1), disengage the retaining tabs that secure the rear air outlets (2) to the rear air outlet housing (3) and gently pry the outlets from the housing (3). Installation-Front Passenger Air Outlet INSTALLATION-FRONT PASSENGER AIR OUTLET 1. Position the passenger side instrument panel air outlet and demister air outlet assembly (2) onto the back of the instrument panel cover (3). CAUTION: Always use the retaining screws supplied with the replacement air outlet. Do not use screws longer then 10 mm. Failure to follow this caution may result in damage to the instrument panel cover. CAUTION: Use care when installing the air outlet retaining screws. To prevent damage to the instrument panel cover, do not overtighten the screws. 2. Install six M 4.2 x 9.5 mm screws (1) to secure the air outlet assembly to the instrument panel cover. Carefully tighten the screws securely. 3. Install the instrument panel cover. 4. Install the instrument panel. Installation-Rear Seat Air Outlets INSTALLATION-REAR SEAT AIR OUTLETS NOTE: The air outlets are retained into the air outlet housing by eight retaining tabs. The air outlets must be first installed onto the bottom set of retaining tabs, then the upper set of tabs can be engaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 13289 1. Position the rear air outlets (1) to the back of the rear air outlet housing (2) and engage the lower set of retaining tabs (3). 2. Gently engage the upper set of retaining tabs (4). Make sure all of the retaining tabs are fully seated. NOTE: Illustration shown with front seat cushions removed for clarity. 3. Position the rear air outlet housing (2) to the rear of the front center seat support (3). 4. Install the two screws (1) that secure the rear air outlet housing to the center seat support. Tighten the screws to 2.2 Nm (20 in. lbs.). Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. NOTE: Take the proper precautions to protect the instrument panel from cosmetic damage. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 13290 1. Remove the instrument panel and place it on a workbench. 2. If required, disconnect the center radio speaker wire harness connector (1) and position it the wire harness lead out of the way. 3. Remove the screw (4) that secures the defroster duct adapter (3) to the instrument panel support. 4. Remove the defroster duct adapter from the defroster duct (5). 5. Remove the six screws (2) that secure the defroster duct to the instrument panel. 6. Remove the defroster duct from the instrument panel. Installation INSTALLATION 1. Position the defroster duct (5) into the instrument panel. 2. Install the six screws (2) that secure the defroster duct to the instrument panel. Tighten the screws to 2.2 Nm (20 in. lbs.). 3. Install the defroster duct adapter (3) onto the defroster duct. 4. Install the screw (4) that secures the defroster duct adapter to the instrument panel support. Tighten the screw to 2.2 Nm (20 in. lbs.). 5. If removed, connect the center radio speaker wire harness connector (1) to the speaker. 6. Install the instrument panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 13291 Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in an accidental airbag deployment and possible personal injury or death. NOTE: Regular Cab model shown. Other models similar. 1. Remove the HVAC housing from the vehicle. 2. Remove the screws (3) that secure the floor distribution duct (1) to the bottom of the HVAC housing (2). 3. Remove the floor distribution duct from the HVAC housing. Installation INSTALLATION NOTE: Regular Cab model shown. Other models similar. 1. Position the floor distribution duct (1) onto the bottom of the HVAC housing (2). 2. Install the screws (3) that secure the floor distribution duct to the HVAC housing. Tighten the screws to 1.1 Nm (10 in. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 13292 3. Install the HVAC housing. Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in an accidental airbag deployment and possible personal injury or death. NOTE: Take the proper precautions to protect the instrument panel from cosmetic damage. 1. Remove the instrument panel and place it on a workbench. 2. Remove the radio. 3. Remove the defroster duct. 4. Remove the two screws (1) that secure the center distribution duct (2) to the instrument panel support (3) and remove the duct. 5. Disconnect the right side instrument panel duct adapter (2) from the right side instrument panel duct (1) and remove the adapter. 6. Remove the screw that secures each intermediate demister duct (3 and 4) to the instrument panel cover. 7. Disconnect the intermediate demister ducts from the demister ducts and remove the intermediate ducts. 8. Disconnect the left side instrument panel duct adapter (6) from the right side instrument panel duct (5) and remove the adapter Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 13293 9. Remove the instrument panel cover. 10. Remove the three screws that secure each instrument panel duct to the instrument panel support and remove the ducts. Installation INSTALLATION 1. Position the instrument panel ducts (1 and 5) onto the instrument panel support. 2. Install the three screws that secure each instrument panel duct to the instrument panel support. Tighten the screws to 2.2 Nm (20 in. lbs.). 3. Install the instrument panel cover. 4. Position the left side instrument panel duct adapter (6) into the instrument panel and connect it to the left panel duct. 5. Position the intermediate demister ducts (3 and 4) into the instrument panel and connect them to the demister ducts. 6. Install the screw that secures each intermediate demister duct to the instrument panel cover. Tighten the screws to 2.2 Nm (20 in. lbs.). 7. Position the right side instrument panel duct adapter (2) into the instrument panel and connect it to the right panel duct. 8. Position the center distribution duct (2) to the instrument panel support (3). 9. Install the two screws (1) that secure the center distribution duct to the instrument panel support. Tighten the screws to 2.2 Nm (20 in. lbs.). 10. Install the defroster duct. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 13294 11. Install the radio. 12. Install the instrument panel. Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in an accidental airbag deployment and possible personal injury or death. NOTE: Take the proper precautions to protect the instrument panel from cosmetic damage. 1. Remove the instrument panel and place it on a workbench. 2. Remove the radio. 3. Remove the defroster duct. 4. Remove the two screws (1) that secure the center distribution duct (2) to the instrument panel support (3) and remove the duct. 5. Disconnect the right side instrument panel duct adapter (2) from the right side instrument panel duct (1) and remove the adapter. 6. Remove the screw that secures each intermediate demister duct (3 and 4) to the instrument panel cover. 7. Disconnect the intermediate demister ducts from the demister ducts and remove the intermediate ducts. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 13295 8. Disconnect the left side instrument panel duct adapter (6) from the right side instrument panel duct (5) and remove the adapter 9. Remove the instrument panel cover. 10. Remove the two screws that secure each demister duct to the instrument panel cover and remove the ducts. Installation INSTALLATION 1. Position the demister ducts onto the instrument panel cover. 2. Install the two screws that secure each demister duct to the instrument panel cover. Tighten the screws to 2.2 Nm (20 in. lbs.). 3. Install the instrument panel cover. 4. Position the left side instrument panel duct adapter (6) into the instrument panel and connect it to the left panel duct. 5. Position the intermediate demister ducts (3 and 4) into the instrument panel and connect them to the demister ducts. 6. Install the screw that secures each intermediate demister duct to the instrument panel cover. Tighten the screws to 2.2 Nm (20 in. lbs.). 7. Position the right side instrument panel duct adapter (2) into the instrument panel and connect it to the right panel duct. 8. Position the center distribution duct (2) to the instrument panel support (3). 9. Install the two screws (1) that secure the center distribution duct to the instrument panel support. Tighten the screws to 2.2 Nm (20 in. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 13296 10. Install the defroster duct. 11. Install the radio. 12. Install the instrument panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations Component ID: 387 Component : SENSOR-AMBIENT AIR TEMPERATURE Connector: Name : SENSOR-AMBIENT AIR TEMPERATURE Color : BLACK # of pins : 2 Pin Description Circuit 1 AAT SIGNAL G31 20VT/LG 2 AAT RETURN G930 20VT/TN Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 13300 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 13301 Ambient Temperature Sensor / Switch HVAC: Diagrams Component ID: 387 Component : SENSOR-AMBIENT AIR TEMPERATURE Connector: Name : SENSOR-AMBIENT AIR TEMPERATURE Color : BLACK # of pins : 2 Pin Description Circuit 1 AAT SIGNAL G31 20VT/LG 2 AAT RETURN G930 20VT/TN Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 13302 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Description Ambient Temperature Sensor / Switch HVAC: Description and Operation Description DESCRIPTION The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the left side of the radiator yoke, behind the radiator grille and in front of the engine compartment. The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Description > Page 13305 Ambient Temperature Sensor / Switch HVAC: Description and Operation Operation OPERATION The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent by the Totally Integrated Power Module (TIPM). The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the TIPM. Based upon the resistance in the sensor, the TIPM senses a specific voltage on the temperature sensor signal circuit. The TIPM then translates the voltage into a temperature reading that it sent over the Programmable Communications Interface (PCI) data bus circuit to other modules utilizing temperature information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Page 13306 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection AMBIENT TEMPERATURE SENSOR The temperature function is supported by the ambient temperature sensor, a wiring circuit, and the Totally Integrated Power Module (TIPM). When the sensor is exposed to temperatures above 60° C (140° F), or if the sensor circuit is shorted, 60° C (130/140° F) will appear in the display in place of the temperature. When the sensor is exposed to temperatures below - 40° C (- 40° F) or if the sensor circuit is open, - 40° C (- 40° F) will appear in the display for Compass Mini - Trip Computer (CMTC) equipped vehicles and - -° C (- -° F) will be displayed on Electronic Vehicle Information Center (EVIC) equipped vehicles. The ambient temperature sensor circuit can be diagnosed using the following Temperature System Test, and Sensor Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, test the Compass Mini - Trip Computer (CMTC) or Electronic Vehicle Information Center (EVIC) as applicable. TEMPERATURE SYSTEM TEST For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. NOTE: Temperature readings do not update immediately. Allow up to 60 seconds after the ignition switch is turned to the On position for readings to meet test specifications. 1. Turn the ignition switch to the Off position. Disconnect the wire harness connector from the ambient temperature sensor. 2. Turn the ignition switch to the On position. The CMTC display should now read - 40° C (- 40° F) or the EVIC display should now read - -° C (- ° F). If OK, go to STEP 3. If not OK, repair the shorted sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 3. Turn the ignition switch to the Off position. Taking care not to damage the wire terminals, connect a jumper wire between the two terminals in the body half of the ambient temperature sensor harness connector. 4. Turn the ignition switch to the On position. The CMTC or EVIC display should now read 60° C (130/140° F). If OK, go to STEP 5. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 5. Clear any Diagnostic Trouble Codes that may have been set while performing the test. Perform further diagnosis of the Compass Mini - Trip Computer (CMTC) or Electronic Vehicle Information Center (EVIC) as applicable. SENSOR TEST 1. Turn the ignition switch to the Off position. Disconnect the ambient temperature sensor harness connector. 2. Measure the resistance of the ambient temperature sensor. At - 40° C (- 40° F), the sensor resistance is 336 kilohms. At 55° C (130° F), the sensor resistance is 2.488 kilohms. The sensor resistance should read between these two values. If OK, perform further diagnosis of the Compass Mini - Trip Computer (CMTC) or Electronic Vehicle Information Center (EVIC) as applicable. If not OK, replace the inoperative ambient temperature sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Service and Repair > Removal Ambient Temperature Sensor / Switch HVAC: Service and Repair Removal REMOVAL 1. Open the hood. 2. Disconnect and isolate the battery negative cable. 3. Working on the underside of the hood, remove screw holding sensor to hood panel. 4. Disconnect the sensor electrical connector and remove sensor from vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Service and Repair > Removal > Page 13309 Ambient Temperature Sensor / Switch HVAC: Service and Repair Installation INSTALLATION 1. Connect the sensor electrical connector. 2. Working on the underside of the hood, install screw holding sensor to hood panel. 3. Connect the battery negative cable. 4. Close the hood. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations Blower Motor: Locations Component ID: 217 Component : MOTOR-BLOWER Connector: Name : MOTOR-BLOWER Color : BLACK # of pins : 2 Pin Description Circuit 1 BLOWER MOTOR HIGH DRIVER C70 10DB/YL 2 FUSED IGNITION SWITCH OUTPUT (RUN-START) F942 10PK/LG Component Location - 40 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 13313 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Blower Motor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13316 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13317 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13318 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13319 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13320 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13321 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13322 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13323 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13324 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13325 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13326 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13327 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13328 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13329 Blower Motor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13330 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13331 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13332 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13333 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13334 Blower Motor: Connector Views Component ID: 217 Component : MOTOR-BLOWER Connector: Name : MOTOR-BLOWER Color : BLACK # of pins : 2 Pin Description Circuit 1 BLOWER MOTOR HIGH DRIVER C70 10DB/YL 2 FUSED IGNITION SWITCH OUTPUT (RUN-START) F942 10PK/LG Component Location - 40 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13335 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Description Blower Motor: Description and Operation Description DESCRIPTION The blower motor (1) is used to control the velocity of air moving through the HVAC housing by spinning the blower wheel (3) within the HVAC air inlet housing at the selected speed. The blower motor is a 12-volt, direct current (DC) motor mounted within a plastic housing with an integral wire harness connector (2) and squirrel cage-type blower wheel (3) that is secured to the blower motor shaft (4). The blower wheel is positioned within the air inlet housing on the passenger side end of the HVAC housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Description > Page 13338 Blower Motor: Description and Operation Operation OPERATION The blower motor is used to control the velocity of air moving through the HVAC housing by spinning the blower wheel within the HVAC air inlet housing at the selected speed. The blower motor will operate whenever the ignition switch is in the Run position and the blower motor control is in any position except Off. The blower motor receives battery current through the totally integrated power module (TIPM) whenever the ignition switch is in the Run position. Blower motor speed is controlled by regulating the ground path through or around the blower motor resistor and through the blower motor control located within the A/C-heater control. The blower motor can be accessed for service from underneath the instrument panel. NOTE: The blower motor is supplied with a 12V feed from the TIPM, through the blower motor resistor, whenever the ignition switch is in the RUN position. Due to an open circuit condition within the blower motor control switch the TIPM is UNABLE to detect an OPEN circuit for the blower motor. The blower motor control system is diagnosed using a scan tool. The blower motor and blower motor wheel are factory balanced as an assembly and cannot be adjusted or repaired and must be replaced if found inoperative or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Page 13339 Blower Motor: Testing and Inspection BLOWER MOTOR WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. NOTE: The blower motor is supplied with a 12V feed from the TIPM, through the blower motor resistor, whenever the ignition switch is in the RUN position. Due to an open circuit condition within the blower motor control switch the TIPM is UNABLE to detect an OPEN circuit for the blower motor. To determine if an open condition exists within the blower motor circuit wiring, it is necessary to disconnect the negative battery cable and check for continuity within the blower motor circuits using an ohmmeter. OPERATION Possible causes of an inoperative blower motor include: - Open fuse - Inoperative blower motor resistor - Inoperative blower motor switch - Inoperative blower motor - Inoperative blower motor circuit wiring or wire harness connectors NOISE To determine if the blower motor is the source of the noise, simply switch the blower motor from Off to On. To verify that the blower motor is the source of the noise, unplug the blower motor wire harness connector and operate the heater-A/C system. If the noise goes away, possible causes include: - Foreign material on fresh air inlet screen - Foreign material in blower wheel - Foreign material in HVAC housing - Improper blower motor mounting - Deformed or damaged blower wheel - Worn blower motor bearings or brushes VIBRATION Possible causes of a blower motor vibration include: - Improper blower motor mounting - Foreign material in blower wheel - Deformed or damaged blower wheel - Worn blower motor bearings Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Removal Blower Motor: Service and Repair Removal REMOVAL NOTE: The blower motor is located on the passenger side of the vehicle under the instrument panel. The blower motor can be removed from the vehicle without having to remove the HVAC housing. 1. Disconnect and isolate the negative battery cable. 2. Remove the passenger side cowl trim panel. 3. Disconnect the HVAC wire harness lead (1) from the blower motor (2). 4. Remove the HVAC wire harness lead from the two wire harness retainers (3). 5. Remove the three screws (4) that secure the blower motor to the bottom of the HVAC housing (5). 6. Remove the blower motor from the HVAC housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Removal > Page 13342 Blower Motor: Service and Repair Installation INSTALLATION 1. Position the blower motor (2) into the bottom of the HVAC housing (5). 2. Install the three screws (4) that secure the blower motor to the HVAC housing. Tighten the screws to 1.7 Nm (15 in. lbs.). 3. Connect the HVAC wire harness lead (1) to the blower motor and install the wire harness lead into the two wire harness retainers (3). 4. Install the passenger side cowl trim panel. 5. Reconnect the negative battery cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations Blower Motor Resistor: Locations Component ID: 242 Component : RESISTOR-BLOWER MOTOR Connector: Name : RESISTOR-BLOWER MOTOR Color : BLACK # of pins : 4 Pin Description Circuit 1 BLOWER MOTOR M1 DRIVER C72 16DB/OR 2 BLOWER MOTOR HIGH DRIVER C70 12DB/YL 3 BLOWER MOTOR LOW DRIVER C71 16DB/BR 4 BLOWER MOTOR M2 DRIVER C73 14DB/VT Component Location - 40 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 13346 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 13347 Blower Motor Resistor: Diagrams Component ID: 242 Component : RESISTOR-BLOWER MOTOR Connector: Name : RESISTOR-BLOWER MOTOR Color : BLACK # of pins : 4 Pin Description Circuit 1 BLOWER MOTOR M1 DRIVER C72 16DB/OR 2 BLOWER MOTOR HIGH DRIVER C70 12DB/YL 3 BLOWER MOTOR LOW DRIVER C71 16DB/BR 4 BLOWER MOTOR M2 DRIVER C73 14DB/VT Component Location - 40 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 13348 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Description Blower Motor Resistor: Description and Operation Description DESCRIPTION The blower motor resistor is mounted to the bottom of the HVAC housing, directly behind the glove box. The blower motor resistor consists of a molded plastic mounting plate (1) with an integral wire connector receptacle (2). Concealed behind the mounting plate are coiled resistor wires contained within a ceramic heat sink (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Description > Page 13351 Blower Motor Resistor: Description and Operation Operation OPERATION The blower motor resistor is connected to the vehicle electrical system through a dedicated wire lead and connector of the HVAC wire harness. The blower motor resistor has multiple resistor wires, each of which will reduce the current flow through the blower motor to change the blower motor speed. The blower motor control for the heating-A/C system directs the ground path for the blower motor through the correct resistor wire to obtain the selected speed. With the blower motor control in the lowest speed position, the ground path for the blower motor is applied through all of the resistor wires. Each higher speed selected with the blower motor control applies the blower motor ground path through fewer of the resistor wires, increasing the blower motor speed. The blower motor resistor cannot be adjusted or repaired and must be replaced if found inoperative or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Page 13352 Blower Motor Resistor: Testing and Inspection BLOWER MOTOR RESISTOR WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. NOTE: The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector from the blower motor resistor . 3. Using an ohmmeter, check for continuity between all of the blower motor resistor terminals. In each case there should be continuity. If OK, repair the wire harness circuits between the blower motor speed control and the blower motor resistor or blower motor as required. If not OK, replace the inoperative blower motor resistor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Removal Blower Motor Resistor: Service and Repair Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in an accidental airbag deployment and possible personal injury or death. WARNING: The blower motor resistor may get very hot during normal operation. If the blower motor was turned on prior to servicing the blower motor resistor, wait five minutes to allow the blower motor resistors to cool before performing diagnosis or service. Failure to take this precaution can result in possible personal injury. 1. Disconnect and isolate the negative battery cable. 2. Reach under the instrument panel near the blower motor (5) and disconnect the wire harness connector (2) from the blower motor resistor (4). 3. Remove the two screws (1) that secure the blower motor resistor to the HVAC housing (3). 4. Remove the blower motor resistor from the HVAC housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Removal > Page 13355 Blower Motor Resistor: Service and Repair Installation INSTALLATION 1. Position the blower motor resistor (4) into the opening of the HVAC housing (3) near the blower motor (5). 2. Install the two screws (1) that secure the blower motor resistor to the HVAC housing. Tighten the screws to 1.1 Nm (10 in. lbs.). 3. Connect the wire harness connector (2) to the blower motor resistor. 4. Reconnect the negative battery cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair Chrysler provides no information on a Cabin Air Filter for this vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Locations Compressor Clutch: Locations Component ID: 69 Component : CLUTCH-A/C COMPRESSOR Connector: Name : CLUTCH-A/C COMPRESSOR Color : BLACK # of pins : 2 Pin Description Circuit 1 A/C CLUTCH CONTROL OUTPUT C3 20DB/YL 2 GROUND Z153 20BK/GY Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Locations > Page 13363 Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Locations > Page 13364 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Locations > Page 13365 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Locations > Page 13366 Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Locations > Page 13367 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Locations > Page 13368 Compressor Clutch: Diagrams Component ID: 69 Component : CLUTCH-A/C COMPRESSOR Connector: Name : CLUTCH-A/C COMPRESSOR Color : BLACK # of pins : 2 Pin Description Circuit 1 A/C CLUTCH CONTROL OUTPUT C3 20DB/YL 2 GROUND Z153 20BK/GY Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Locations > Page 13369 Component Location - 5 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Locations > Page 13370 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Locations > Page 13371 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Locations > Page 13372 Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Locations > Page 13373 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Description and Operation > Description Compressor Clutch: Description and Operation Description DESCRIPTION NOTE: Denso 10S17 A/C clutch assembly shown. Visteon HS-18 compressor similar. The A/C compressor clutch assembly consists of a stationary electromagnetic field coil (4), bearing and pulley assembly (3), shims (7) and a clutch plate (2) that is splined to the compressor shaft and secured by a bolt (1). These components provide the means to engage and disengage the A/C compressor from the engine accessory drive belt. The A/C clutch bearing and pulley assembly on both A/C compressors are retained to the front of the compressor with a snap ring (6). The A/C clutch field coil on the Denso 10S17 A/C compressor is also retained to the front of the compressor using a snap ring (5). The field coil on the Visteon HS-18 compressor is pressed onto the front of the compressor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Description and Operation > Description > Page 13376 Compressor Clutch: Description and Operation Operation OPERATION The A/C compressor clutch components provide the means to engage and disengage the A/C compressor from the engine accessory drive belt. When the electromagnetic A/C clutch field coil is energized, it magnetically draws the clutch plate into contact with the clutch pulley and drives the compressor shaft. When the coil is not energized, the pulley freewheels on the clutch hub bearing, which is part of the pulley assembly. A/C compressor clutch engagement is controlled by the powertrain control module (PCM) or the engine control module (ECM), depending on engine application. When the A/C-heater control is set to any A/C position, it sends a request signal on the CAN-B bus to the totally integrated power module (TIPM), which then transfers the request on the CAN-C Bus to the PCM/ECM, which determines if operating conditions are correct for A/C clutch engagement. When all operating conditions have been met, the PCM/ECM sends a signal on a dedicated hard-wired circuit back to the totally integrated power module (TIPM) to energize the internal A/C clutch high side driver. When energized, the A/C clutch high side driver provides battery current to the A/C clutch field coil. The A/C clutch control system is diagnosed using a scan tool. The A/C compressor clutch components cannot be adjusted or repaired and must be replaced if found inoperative or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Diagnosis And Testing Compressor Clutch: Testing and Inspection Diagnosis And Testing A/C COMPRESSOR CLUTCH COIL The A/C compressor clutch coil electrical circuit is controlled by the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) through the totally integrated power module (TIPM). Begin testing of a suspected compressor clutch coil problem by performing the preliminary checks. PRELIMINARY CHECKS 1. Using a scan tool, check for diagnostic trouble codes (DTCs) in the A/C-heater control, TIPM, PCM/ECM and if equipped with the 8.3L engine, the gateway module. If no DTCs are found, go to STEP 2. If any DTCs are found, repair as required. 2. If the A/C compressor clutch still will not engage, verify the refrigerant charge level. If the refrigerant charge level is OK, go to TESTS. If the refrigerant charge level is not OK, adjust the refrigerant charge as required. TESTS 3. Verify the battery state of charge. 4. Connect an ammeter (0 to 10 ampere scale selected) in series with the clutch coil feed terminal. Connect a voltmeter (0 to 20 volt scale selected) to measure voltage across the battery and the clutch coil. 5. With the A/C-heater control in the A/C mode and the blower motor at low speed, start the engine and allow it to run at a normal idle speed. 6. The A/C compressor clutch should engage immediately, and the clutch coil supply voltage should be within two volts of the battery voltage. If the coil supply voltage is OK, go to STEP 5. If the coil supply voltage is not within two volts of battery voltage, test the clutch coil feed circuit for excessive voltage drop and repair as necessary. 7. For the acceptable A/C clutch coil current draw specifications. Specifications apply for a work area temperature of 21° C (70° F). If voltage is more than 12.5 volts, add electrical loads by turning on electrical accessories until voltage reads below 12.5 volts. a. If the A/C clutch coil current reading is zero, the coil is open and must be replaced. b. If the A/C clutch coil current reading is above specifications, the coil is shorted and must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Diagnosis And Testing > Page 13379 Compressor Clutch: Testing and Inspection A/C Clutch Plate Inspection A/C CLUTCH PLATE INSPECTION NOTE: The A/C clutch can be serviced in the vehicle. The refrigerant system can remain fully-charged during compressor clutch, pulley and bearing assembly, or coil replacement. Examine the friction surfaces of the pulley and the clutch plate (2) for wear. The pulley and clutch plate should be replaced if there is excessive wear or scoring. If the friction surfaces are oily, inspect the shaft and nose area of the A/C compressor (1) for refrigerant oil. If refrigerant oil is found, the compressor shaft seal is leaking and the A/C compressor must be replaced. Check the pulley bearing for roughness or excessive leakage of grease. Replace the pulley and bearing assembly, if required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Procedures Compressor Clutch: Procedures A/C CLUTCH BREAK-IN After a new A/C compressor clutch has been installed, cycle the compressor clutch approximately 20 times (5 seconds on, then 5 seconds off). During this procedure, set the A/C-heater controls to the A/C Recirculation Mode, the blower motor in the highest speed position, and the engine speed at 1500 to 2000 rpm. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher compressor clutch torque capability. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Procedures > Page 13382 Compressor Clutch: Removal and Replacement Denso A/C Compressor DENSO A/C COMPRESSOR NOTE: The compressor clutch assembly can be serviced with the refrigerant system fully-charged. NOTE: Typical A/C compressor and clutch assembly shown in illustrations. 1. Disconnect and isolate the negative battery cable. 2. Remove the accessory drive belt. 3. Disconnect the engine wire harness from the compressor clutch field coil connector (1) located on the top of the A/C compressor (5). 4. Remove the bolts that secure the A/C compressor to the engine and support the A/C compressor. 5. Carefully remove the compressor clutch field coil connector and wire lead from the connector bracket (2). 6. Remove the compressor shaft bolt (3). A band-type oil filter wrench or a strap wrench may be used to hold the clutch plate (4) from rotating during bolt removal. CAUTION: Do not pry between the clutch plate and the pulley and bearing assembly to remove the clutch plate from the compressor Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Procedures > Page 13383 shaft as this may damage the clutch plate. NOTE: Use care not to lose any clutch shim(s) during removal of the clutch plate, as they may be reused during the clutch plate installation process. 7. Tap the clutch plate (2) lightly with a plastic mallet to release it from the splines on the compressor shaft (1) and remove the clutch plate and shim(s) (3). 8. Using Snap Ring Pliers 9764 or equivalent (1), remove the snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor and remove the pulley and bearing assembly. 9. Using Snap Ring Pliers 9764 or equivalent (1), remove the snap ring (4) that secures the compressor clutch field coil (2) to the front of the A/C compressor (3) and remove the field coil. Visteon A/C Compressor VISTEON A/C COMPRESSOR NOTE: The A/C compressor clutch can be serviced in the vehicle. The refrigerant system can remain fully-charged during compressor clutch, pulley and bearing assembly or field coil replacement. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Procedures > Page 13384 1. Disconnect and isolate negative battery cable. 2. Remove the accessory drive belt. 3. Raise and support the vehicle. 4. Disconnect the engine wire harness from the clutch field coil connector (4). 5. Remove the bolts that secure the A/C compressor (5) to the mounting bracket. 6. Remove the A/C compressor from the mounting bracket and support the compressor while servicing the clutch. 7. Using compressor clutch holding fixture (Special Tool 9351 in Kit 9349) (1), remove the bolt (2) that secures the clutch plate (3) to the compressor shaft. NOTE: The clutch plate can be removed from the compressor shaft by hand or, if required, pressed off with an 8 x 1.25 mm bolt. NOTE: Clutch plate shim(s) may remain inside the hub of the clutch plate. Be sure to remove all of the shims from inside the hub or from the end of the compressor shaft. 8. Remove the clutch plate and shim(s) from the A/C compressor. If required, install a 8 x 1.25 mm bolt into the center of the clutch plate and turn the bolt clockwise until the clutch plate is completely removed from the A/C compressor. 9. Using Snap Ring Pliers 9764 or equivalent (1), remove the snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Procedures > Page 13385 NOTE: The pulley and bearing assembly can be removed from the compressor by hand or, if required, with a two jaw puller. 10. Remove the pulley and bearing assembly (1) from the front of the A/C compressor (2). If required, install a two jaw puller (3) and turn the puller center-bolt clockwise until the pulley and bearing assembly is completely removed. 11. Remove the plastic retaining clip (1) and the screw (2) that secures the clutch field coil wire lead and connector (3) to the A/C compressor (4). 12. Using compressor field coil remover (Special Tool 9354 in Kit 9349) (1) and a two jaw puller (2), remove the clutch field coil (3) from the front of the A/C compressor (4). Denso A/C Compressor DENSO A/C COMPRESSOR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Procedures > Page 13386 NOTE: Typical A/C compressor and clutch assembly shown in illustrations. 1. Align the dowel pin on the back of the compressor clutch field coil (2) with the hole in the front of the A/C compressor (3) and position the field coil onto the compressor. Be certain that the compressor clutch field coil wire lead is properly routed so that it is not pinched between the A/C compressor and the field coil. CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor. NOTE: A new snap ring must be used to secure the compressor clutch field coil to the A/C compressor. The bevel side of the snap ring must face outward and both snap ring eyelets must be oriented to the right or to the left of the field coil dowel pin location on the A/C compressor. 2. Using Snap Ring Pliers 9764 or equivalent (1), install the snap ring (4) that secures the compressor clutch field coil to the front of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove and oriented correctly. CAUTION: Be certain to position the compressor clutch field coil wire lead so that it is not damaged during A/C compressor pulley and bearing installation. CAUTION: When installing the pulley and bearing assembly, DO NOT mar the friction surfaces of the pulley or premature failure of the clutch will result. 3. Install the pulley and bearing assembly (1) onto the front of the A/C compressor. If necessary, tap the pulley gently with a block of wood (2) placed on the pulley friction surface. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Procedures > Page 13387 CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor. NOTE: A new snap ring must be used to secure the pulley and bearing assembly to the A/C compressor. The bevel side of the snap ring must face outward. 4. Using Snap Ring Pliers 9764 or equivalent (1), install the snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove. 5. If the original clutch plate (2) and pulley and bearing assembly are to be reused, reinstall the original shim(s) (3) onto the compressor shaft (1). If a new clutch plate and pulley and bearing assembly are being used, install a trial stack of shims 2.54 mm (0.010 in.) thick onto the compressor shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Procedures > Page 13388 6. Install the clutch plate (4) onto the front of the A/C compressor (5). 7. Install the compressor shaft bolt (3). Tighten the bolt to 19 Nm (168 in. lbs.). NOTE: The shims may compress after tightening the shaft bolt. Check the air gap in four or more places to verify the air gap is correct. Spin the pulley before performing a final check of the air gap. NOTE: On models with the clutch plate recessed into the pulley, use a 90° wire gap gauge to measure the clutch air gap. On other models, use a blade type feeler gauge to measure the air gap. 8. With the clutch plate assembled tight against the shim(s), measure the air gap between the clutch plate and the pulley and bearing assembly. The air gap should be between 0.35 - 0.60 mm (0.014 - 0.024 in.). If the air gap is not between specifications, add or subtract shims as needed until the correct air gap is obtained. CAUTION: Be certain that the compressor clutch field coil wire harness is properly routed so that it is not pinched between the A/C compressor and the field coil connector bracket. 9. Carefully route the compressor clutch field coil wire lead behind the connector bracket (2). 10. Install the compressor clutch field coil connector (1) onto the connector bracket. 11. Position the A/C compressor to the engine and install the retaining bolts. 12. Connect the engine wire harness to the compressor clutch field coil connector. 13. Install the accessory drive belt. 14. Reconnect the negative battery cable. Visteon A/C Compressor VISTEON A/C COMPRESSOR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Procedures > Page 13389 1. Position the A/C clutch field coil (1) squarely onto the front of the A/C compressor (2). CAUTION: Position the A/C clutch field coil so that the coil positioning tabs and the wire harness lead are oriented in the correct direction. Failure to correctly position the field coil on the A/C compressor will result in field coil damage. 2. Align the field coil positioning tabs to the recessed area at the front of the A/C compressor and install the clutch field coil onto the compressor using a two jaw puller (3), compressor field coil installer (Special Tool 9352 in Kit 9349) (4) and the compressor field coil installer spacer (Special Tool 9353 in Kit 9349) (5). 3. Position the clutch field coil wire lead and connector (3) to the A/C compressor (4) and install the plastic retaining clip (1) and the screw (2) that secures the wire lead to the compressor. Tighten the screw to 4 Nm (35 in. lbs.). 4. Align the pulley and bearing assembly (1) squarely onto the front of the A/C compressor (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Procedures > Page 13390 NOTE: A distinct change of sound during the clutch pulley tapping process indicates that the pulley and bearing assembly has bottomed out against the compressor housing. 5. Using clutch pulley installer (Special Tool 9355 in Kit 9349) (3) and a hammer (4), install the pulley and bearing assembly onto the front of the A/C compressor. Tap the installer with a hammer until the pulley and bearing assembly has bottomed against the compressor housing. CAUTION: If the snap ring is not fully seated in the groove it will vibrate out, resulting in clutch failure and severe damage to the A/C compressor. NOTE: Install the snap ring with the beveled side of the snap ring facing outward. 6. Using Snap Ring Pliers 9764 or equivalent (1), install the snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor (4). Make sure the snap ring is properly seated in the groove. 7. Verify that there is adequate clearance for the clutch field coil wire lead and connector (4) between the compressor housing and the pulley. NOTE: When installing an original or a new clutch assembly, try the original shims first. When installing a clutch onto a compressor that previously did not have a clutch, use the 1.0, 0.50 and 0.13 millimeter (0.040, 0.020 and 0.005 inch) shims from the clutch hardware package which is provided with the new clutch. 8. Install the clutch shims onto the compressor shaft. 9. Using compressor clutch holding fixture (Special Tool 9351 in Kit 9349) (1), install the bolt (2) that secures the clutch plate (3) to the A/C compressor (5). Hold the clutch plate stationary with the holding fixture and tighten the bolt to 15 Nm (133 in. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Procedures > Page 13391 10. Using a feeler gauge (1), check the air gap between the clutch plate (2) and the pulley and bearing assembly (3). If the air gap is not 0.35 to 0.75 millimeter (0.014 to 0.030 inch), add or subtract shims as required. 11. Position the A/C compressor (4) onto the mounting bracket. 12. Install the bolts that secure the A/C compressor to the mounting bracket. Tighten the bolts to 23 Nm (17 ft. lbs.). 13. Connect the engine wire harness to the compressor clutch field coil connector (5). 14. Lower the vehicle. 15. Install the accessory drive belt. 16. Reconnect the negative battery cable. 17. Perform the Clutch Break-in Procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Description Condenser HVAC: Description and Operation Description DESCRIPTION The A/C condenser is located in the front of the engine compartment behind the grille. The A/C condenser is a heat exchanger that allows the high-pressure refrigerant gas being discharged by the A/C compressor to give up its heat to the air passing over the condenser fins, which causes the refrigerant to cool and change to a liquid state. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Description > Page 13396 Condenser HVAC: Description and Operation Operation OPERATION When air passes through the fins of the A/C condenser, the high-pressure refrigerant gas within the A/C condenser gives up its heat. The refrigerant then condenses as it leaves the A/C condenser and becomes a high-pressure liquid. The volume of air flowing over the condenser fins is critical to the proper cooling performance of the A/C system. Therefore, it is important that there are no objects placed in front of the radiator grille openings at the front of the vehicle or foreign material on the condenser fins that might obstruct proper air flow. Also, any factory-installed air seals or shrouds must be properly reinstalled following radiator or A/C condenser service. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C condenser has no serviceable parts except for the O-ring seals and gaskets. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever a refrigerant line is removed from the A/C condenser. The A/C condenser cannot be repaired and must be replaced if leaking or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Removal Condenser HVAC: Service and Repair Removal 5.9L/6.7L DIESEL ENGINES WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. NOTE: Illustration shown with air seal removed for clarity. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system. 3. Remove the air seal from the right end of the A/C condenser (5) to gain access to the refrigerant line fittings. 4. Disconnect the A/C discharge line (1) and the A/C liquid line (3) from the A/C condenser (5). 5. Remove the four bolts (2, 4, 6 and 7) that secure the A/C condenser to the charge air cooler. 6. Remove the A/C condenser from the engine compartment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Removal > Page 13399 Condenser HVAC: Service and Repair Installation 5.9L/6.7L DIESEL ENGINES CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. NOTE: If only the A/C condenser is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: Illustration shown with air seal removed for clarity. 1. Position the A/C condenser (5) into the engine compartment. 2. Install the four bolts (2, 4, 6 and 7) that secure the A/C condenser to the charge air cooler. Tighten the bolts to 10.5 Nm (95 in. lbs.). 3. Remove the tape or plugs from the discharge and liquid line fittings and condenser ports. 4. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Connect the A/C discharge line (1) and the A/C liquid line (3) onto the A/C condenser. NOTE: Be certain that each of the radiator and condenser air seals are installed in their proper locations. These air seals are required for the A/C and engine cooling systems to perform as designed. 6. Position the air seal over the right end of the A/C condenser and install the air seal retainers. 7. Reconnect the negative battery cable. 8. Evacuate the refrigerant system. 9. If the A/C condenser is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. Use only Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Removal > Page 13400 refrigerant oil of the type recommended for the A/C compressor in the vehicle. 10. Charge the refrigerant system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Condenser Fan Motor > Component Information > Locations Condenser Fan Motor: Locations Component ID: 218 Component : MOTOR-CONDENSER FAN Connector: Name : MOTOR-CONDENSER FAN Color : BLACK # of pins : 2 Qualifier : (GAS) A GROUND Z823 12BK/DG B CONDENSER FAN CONTROL OUTPUT C123 12LB/WT Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Condenser Fan Motor > Component Information > Locations > Page 13405 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Condenser Fan Motor > Component Information > Locations > Page 13406 Condenser Fan Motor: Diagrams Component ID: 218 Component : MOTOR-CONDENSER FAN Connector: Name : MOTOR-CONDENSER FAN Color : BLACK # of pins : 2 Qualifier : (GAS) A GROUND Z823 12BK/DG B CONDENSER FAN CONTROL OUTPUT C123 12LB/WT Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Condenser Fan Motor > Component Information > Locations > Page 13407 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations Control Assembly: Locations Component ID: 78 Component : CONTROL-A/C-HEATER Connector: Name : CONTROL-A/C-HEATER C1 Color : BLACK # of pins : 16 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN) F921 20PK/LB 2 GROUND Z24 20BK/OR 3 FUSED B(+) A919 20RD 4-5-6 EVAPORATOR TEMPERATURE SENSOR SIGNAL C21 20DB/LG 7 SENSOR GROUND C121 20DB/DG 8 PANEL LAMPS DRIVER E16 20OR/GY 9 BLEND DOOR DRIVER C61 20DB/LG 10 MODE DOOR 2 DRIVER C29 20DB 11 RECIRCULATION DOOR DRIVER C32 20DB/TN 12 MODE DOOR 1 DRIVER C801 20DB/OR 13 COMMON DOOR DRIVER C34 20DB/LB 14 PASSENGER BLEND DOOR DRIVER C33 20LB/BR 15 CAN B BUS (-) D54 20WT 16 CAN B BUS (+) D55 20WT/OR Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 13411 Connector: Name : CONTROL-A/C-HEATER C2 Color : BLACK # of pins : 10 Pin Description Circuit 1-2 BLOWER MOTOR LOW DRIVER C71 16DB/BR 3 BLOWER MOTOR M2 DRIVER C73 14DB/VT 4-5 GROUND Z134 10BK/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 13412 6-7 BLOWER MOTOR M1 DRIVER C72 16DB/OR 8-9-10 BLOWER MOTOR HIGH DRIVER C70 10DB/YL Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions Control Assembly: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 13415 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 13416 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 13417 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 13418 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 13419 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 13420 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 13421 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 13422 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 13423 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 13424 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 13425 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 13426 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 13427 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 13428 Control Assembly: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 13429 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 13430 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 13431 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 13432 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 13433 Control Assembly: Connector Views Component ID: 78 Component : CONTROL-A/C-HEATER Connector: Name : CONTROL-A/C-HEATER C1 Color : BLACK # of pins : 16 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN) F921 20PK/LB 2 GROUND Z24 20BK/OR 3 FUSED B(+) A919 20RD 4-5-6 EVAPORATOR TEMPERATURE SENSOR SIGNAL C21 20DB/LG 7 SENSOR GROUND C121 20DB/DG 8 PANEL LAMPS DRIVER E16 20OR/GY 9 BLEND DOOR DRIVER C61 20DB/LG 10 MODE DOOR 2 DRIVER C29 20DB 11 RECIRCULATION DOOR DRIVER C32 20DB/TN 12 MODE DOOR 1 DRIVER C801 20DB/OR 13 COMMON DOOR DRIVER C34 20DB/LB 14 PASSENGER BLEND DOOR DRIVER C33 20LB/BR 15 CAN B BUS (-) D54 20WT 16 CAN B BUS (+) D55 20WT/OR Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 13434 Connector: Name : CONTROL-A/C-HEATER C2 Color : BLACK # of pins : 10 Pin Description Circuit 1-2 BLOWER MOTOR LOW DRIVER C71 16DB/BR 3 BLOWER MOTOR M2 DRIVER C73 14DB/VT 4-5 GROUND Z134 10BK/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 13435 6-7 BLOWER MOTOR M1 DRIVER C72 16DB/OR 8-9-10 BLOWER MOTOR HIGH DRIVER C70 10DB/YL Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Manual Single Zone Control Assembly: Description and Operation Manual Single Zone MANUAL SINGLE ZONE The A/C-heater control (1) for the manual temperature control (MTC) single zone heating-A/C system allows one temperature setting for the entire vehicle. All controls are identified by ISO graphic symbols. The A/C-heater control and integral computer is located in the instrument panel and contains: - a push button A/C on/off control (2). The Snowflake button contains an LED that illuminates when the A/C system is in operation. - a push button rear window defogger on/off control (3) when equipped with the optional rear heated window. The defogger button contains an LED that illuminates when the rear window defogger (EBL) system is in operation. - a rotary control knob for recirculation and mode control of the discharged air (4). - a rotary control knob for temperature control of the discharged air (5). - a rotary control knob for fan speed selection and turning the heating-A/C system off (6). The A/C-heater control is diagnosed using a scan tool. The A/C-heater control cannot be adjusted or repaired and must be replaced if found inoperative or damaged. The illumination lamps for the A/C-heater control are available for service replacement. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Manual Single Zone > Page 13438 Control Assembly: Description and Operation Manual Dual Zone MANUAL DUAL ZONE The A/C-heater control (1) for the manual temperature control (MTC) dual zone heating-A/C system allows both the driver and the front seat passenger the ability to individually regulate air temperature for their side of the vehicle. All controls are identified by ISO graphic symbols. The dual zone A/C-heater control and integral computer is located in the instrument panel and contains: - a push button A/C on/off control (2). The Snowflake button contains an LED that illuminates when the A/C system is in operation. - a push button MAX A/C air recirculation control (3). The Recirculation button contains an LED that illuminates when the recirculation function is activated for high A/C demand. - a push button rear window defogger on/off control (4). The defogger button contains an LED that illuminates when the rear window defogger system is in operation. - two slid-type control levers for individual driver and front seat passenger temperature control of the discharged air (5 and 6). - a rotary control knob for mode control of the discharged air (7). - a rotary control knob for fan speed selection and turning the heating-A/C system off (8). The A/C-heater control is diagnosed using a scan tool. The A/C-heater control cannot be adjusted or repaired and must be replaced if found inoperative or damaged. The illumination lamps for the A/C-heater control are available for service replacement. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Removal Control Assembly: Service and Repair Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in an accidental airbag deployment and possible personal injury or death. NOTE: Single zone A/C-heater control shown. Dual zone similar. 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel (1) from the instrument panel and disconnect the wire harness connectors (4 and 5) from the back of the A/C-heater control (2). NOTE: Take the proper precautions to protect the front face of the center bezel from cosmetic damage. 3. Place the center bezel on a workbench and remove the four screws (3) that secure the A/C-heater control to the center bezel and remove the control. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Removal > Page 13441 Control Assembly: Service and Repair Installation INSTALLATION NOTE: Single zone A/C-heater control shown. Dual zone similar. 1. Position the A/C-heater control (2) into the back of the instrument panel center bezel (1). 2. Install the four screws (3) that secure the A/C-heater control to the center bezel. Tighten the screws to 2.2 Nm (20 in. lbs.). 3. Connect the wire harness connectors (4 and 5) to the back of the A/C-heater control and install the instrument panel center bezel. 4. Reconnect the negative battery cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation > Description Coupler HVAC: Description and Operation Description DESCRIPTION Spring-lock type refrigerant line couplers (1 and 4) are used to connect the A/C suction line (6) to the A/C accumulator (5) and, the A/C accumulator and the A/C liquid line to the A/C evaporator tubes (3). Secondary retaining clips (2 and 7) are installed over the connected couplers for added protection. The spring-lock refrigerant line couplers require special disconnect tools for disengaging the two coupler halves. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation > Description > Page 13446 Coupler HVAC: Description and Operation Operation OPERATION The spring-lock type refrigerant line coupler is held together by a garter spring (6) inside a circular cage (7) on the male half of the fitting (1). When the two coupler halves are connected, the flared end of the female fitting (2) slips behind the garter spring inside the cage on the male fitting. The garter spring and cage prevent the flared end of the female fitting from pulling out of the cage. Some applications use a connection indicator ring (4) to help indicate when the two coupler halves are fully connected. O-rings (8) are used to seal the coupler connections. These O-rings are compatible with R-134a refrigerant and must be replaced with O-rings made of the same material. A secondary retaining clip (3) is installed over the connected coupler (5) for added protection. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Removal Coupler HVAC: Service and Repair Removal REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. 1. Recover the refrigerant from the refrigerant system. 2. Remove the secondary retaining clip from the spring-lock type refrigerant line coupler. 3. Fit the proper size A/C line disconnect tool (Special Tool Kit 7193 or equivalent) over the coupler cage (1). 4. Close the two halves of the A/C line disconnect tool around the coupler (2). NOTE: The garter spring may not release if the A/C line disconnect tool is cocked while pushing it into the coupler cage opening. 5. Push the A/C line disconnect tool into the open side of the coupler cage to expand the garter spring (3). Once the garter spring is expanded, pull on the refrigerant line attached to the female half of the coupler until the flange on the female fitting is separated from the garter spring and cage on the male fitting. 6. Open and remove the A/C line disconnect tool from the refrigerant line coupler (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Removal > Page 13449 Coupler HVAC: Service and Repair Installation INSTALLATION 1. Clean any dirt or foreign material from the spring-lock type refrigerant line coupler. 2. Check to make sure that the garter spring (6) is located within the cage (7) of the male half of the refrigerant line coupler (1), and that the garter spring is not damaged. a. If the garter spring is missing, install a new spring by pushing it into the coupler cage opening. b. If the garter spring is damaged, remove it from the coupler cage with a small hook (DO NOT use a screwdriver) and install a new garter spring. CAUTION: Use only the specified O-rings as they are made of a special material for the R-134a system. The use of any other O-rings may allow the connection to leak. 3. Install new O-rings (8) on the male half of the refrigerant line coupler. 4. Lubricate the O-rings, and the inside of the female half of the refrigerant line coupler (2) with clean R-134a refrigerant oil. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Position the female half of the coupler over the male half of the coupler. 6. Push together firmly on the two halves of the refrigerant line coupler until the garter spring in the cage on the male half of the coupler snaps over the flanged end on the female half of the coupler. 7. Make sure that the refrigerant line coupler is fully engaged by firmly pulling the refrigerant lines away from each other on both sides of the coupler. 8. Install the secondary retaining clip (3) over connected coupler cage (5). 9. Evacuate the refrigerant system. 10. Charge the refrigerant system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 13458 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 13459 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 13460 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 13461 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 13462 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 13463 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 13464 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 13465 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 13466 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 13467 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 13468 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 13469 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 13475 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 13476 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 13477 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 13478 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 13479 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 13480 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 13481 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 13482 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 13483 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 13484 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 13485 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 13486 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Description Evaporator Core: Description and Operation Description DESCRIPTION NOTE: Typical A/C evaporator shown. The A/C evaporator (1) for the heating-A/C system is located within the HVAC housing, behind the instrument panel. The A/C evaporator (and insulator (2), when equipped) are positioned in the HVAC housing so that all air entering the housing must pass over the evaporator fins before it is distributed through the heating-A/C system ducts and outlets. However, air passing over the evaporator fins will only be conditioned when the A/C compressor is engaged and circulating refrigerant through the A/C evaporator. The A/C evaporator can be serviced by removing and disassembling the HVAC housing assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Description > Page 13489 Evaporator Core: Description and Operation Operation OPERATION Refrigerant enters the A/C evaporator through the A/C orifice tube as a low-temperature, low-pressure mixture of liquid and gas. As air flows over the fins of the A/C evaporator, the humidity in the air condenses on the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a low-pressure gas when it leaves the A/C evaporator. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C evaporator has no serviceable parts except for the O-ring seals. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever a refrigerant line is removed from the A/C evaporator. The A/C evaporator cannot be repaired and must be replaced if found to be leaking or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Removal Evaporator Core: Service and Repair Removal REMOVAL 1. Remove the HVAC housing and place it on a workbench. 2. Disassemble the HVAC housing to access the A/C evaporator (3). NOTE: If the foam seal for the A/C evaporator tubes is deformed or damaged, the seal must be replaced. 3. Remove the foam seal (1) from around the tubes of the A/C evaporator. 4. Carefully lift the A/C evaporator out of the upper half of the HVAC housing (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Removal > Page 13492 Evaporator Core: Service and Repair Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. NOTE: If only the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. 1. Carefully install the A/C evaporator (3) into the upper half of the HVAC housing (2). NOTE: Make sure that the foam seal is properly positioned. 2. Install the foam seal (1) onto the tubes of the A/C evaporator. 3. Assemble the HVAC housing. 4. Install the HVAC housing. 5. If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations Component ID: 396 Component : SENSOR-EVAPORATOR TEMPERATURE Connector: Name : SENSOR-EVAPORATOR TEMPERATURE Color : NATURAL # of pins : 2 Pin Description Circuit 1 SENSOR GROUND C121 20DB/DG 2 EVAPORATOR TEMPERATURE SENSOR SIGNAL C21 20DB/LG Component Location - 40 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 13496 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 13497 Evaporator Temperature Sensor / Switch: Diagrams Component ID: 396 Component : SENSOR-EVAPORATOR TEMPERATURE Connector: Name : SENSOR-EVAPORATOR TEMPERATURE Color : NATURAL # of pins : 2 Pin Description Circuit 1 SENSOR GROUND C121 20DB/DG 2 EVAPORATOR TEMPERATURE SENSOR SIGNAL C21 20DB/LG Component Location - 40 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 13498 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Description Evaporator Temperature Sensor / Switch: Description and Operation Description DESCRIPTION NOTE: Cutaway of HVAC housing shown for clarity. The evaporator temperature sensor (1) is an electrical thermistor located within a molded plastic case that is inserted into the top of the HVAC housing (2) to measure the temperature of the conditioned air downstream of the A/C evaporator (3). Two terminals within the connector receptacle connect the sensor to the vehicle electrical system through a wire lead and connector of the HVAC wire harness. The external location of the evaporator temperature sensor allows the sensor to be removed or installed without disturbing the refrigerant in the A/C system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Description > Page 13501 Evaporator Temperature Sensor / Switch: Description and Operation Operation OPERATION The evaporator temperature sensor monitors the temperature of the conditioned air downstream of the A/C evaporator and supplies an input signal to the A/C-heater control. The A/C-heater control uses the evaporator temperature sensor input signal to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor will change its internal resistance in response to the temperatures it monitors and is connected to the A/C-heater control through sensor ground circuit and a 5-volt reference signal circuit. As the temperature of the A/C evaporator decreases, the internal resistance of the evaporator temperature sensor decreases. The A/C-heater control uses the monitored voltage reading as an indication of evaporator temperature. The A/C-heater control is programmed to respond to this input by requesting the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) to cycle the A/C compressor clutch as necessary to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor is diagnosed using a scan tool. The evaporator temperature sensor cannot be adjusted or repaired and must be replaced if found inoperative or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Removal Evaporator Temperature Sensor / Switch: Service and Repair Removal REMOVAL NOTE: Illustration shown with instrument panel removed for clarity. 1. Disconnect and isolate the negative battery cable. 2. Remove the glove box from the instrument panel. 3. Disconnect the HVAC wire harness (1) from the evaporator temperature sensor (2) located on the top of the HVAC housing (3). 4. Remove the evaporator temperature sensor from the HVAC housing by pulling the sensor upward while tipping it forward. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Removal > Page 13504 Evaporator Temperature Sensor / Switch: Service and Repair Installation INSTALLATION NOTE: Illustration shown with instrument panel removed for clarity. 1. Install the evaporator temperature sensor (2) into the opening in the top of the HVAC housing (3). Make sure the sensor is fully engage to the housing. 2. Connect the HVAC wire harness (1) to the evaporator temperature sensor. 3. Install the glove box. 4. Reconnect the negative battery cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > Description Expansion Block/Orifice Tube: Description and Operation Description DESCRIPTION The fixed A/C orifice tube is installed in the rear of the A/C liquid line and provides a restriction in the liquid refrigerant line between the A/C condenser and the A/C evaporator. This restriction established the pressure differential between the high and low-pressure sides of the A/C system. The A/C orifice tube includes a diffuser screen (1), O-ring seals (2) to seal it to the inner wall of the A/C liquid line, an inlet filter screen (3) and the fixed orifice (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > Description > Page 13509 Expansion Block/Orifice Tube: Description and Operation Operation OPERATION The fixed A/C orifice tube is used to meter the flow of liquid refrigerant into the A/C evaporator. The high-pressure liquid refrigerant from the A/C condenser expands into a low-pressure liquid as it passes through the metering orifice and diffuser screen of the A/C orifice tube. NOTE: A/C orifice tube size is different between gasoline and diesel engines. Be sure to use the correct A/C liquid line when replacement of the A/C orifice tube is required. The A/C orifice tube is not serviceable and the rear of the A/C liquid line must be replaced if the orifice tube is found inoperative. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > Page 13510 Expansion Block/Orifice Tube: Testing and Inspection A/C ORIFICE TUBE WARNING: The A/C liquid line between the A/C condenser and the A/C orifice tube can become hot enough to burn the skin. Use extreme caution when performing the following test to prevent possible personal injury. NOTE: The A/C orifice tube can be checked for proper operation using the following procedure. However, the A/C orifice tube is only serviced as a part of the A/C liquid line. If the results of this test indicate that the A/C orifice tube is obstructed or missing, the A/C liquid line must be replaced. 1. Confirm that the refrigerant system is properly charged. 2. Start the engine. Turn on the A/C system and confirm that the compressor clutch is engaged. 3. Allow the A/C system to operate for five minutes. 4. Lightly and cautiously touch the A/C liquid line near the condenser outlet at the front of the engine compartment. The A/C liquid line should be hot to the touch. 5. Touch the A/C liquid line near the evaporator inlet at the rear of the engine compartment. The A/C liquid line should be cold to the touch. 6. If there is a distinct temperature differential between the two ends of the A/C liquid line, the A/C orifice tube is in good condition. If there is little or no detectable temperature differential between the two ends of the A/C liquid line, the A/C orifice tube is obstructed or missing and the A/C liquid line must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Description Heater Core: Description and Operation Description DESCRIPTION The heater core (1) is a heat exchanger made of rows of tubes and fins. The heater core is positioned within the HVAC housing through the panel (2) located at the front of the HVAC housing. The heater core tubes (3) are attached to the front of the heater core and are secured to the HVAC housing by a bracket. The heater core can be serviced by removing the HVAC housing assembly from the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Description > Page 13515 Heater Core: Description and Operation Operation OPERATION Engine coolant is circulated through the heater hoses to the heater core at all times. As the coolant flows through the heater core, heat is removed from the engine and is transferred to the heater core tubes and fins. Air directed through the heater core picks up the heat from the heater core fins. The blend-air door(s) allows control of the heater output air temperature by regulating the amount of air flowing through the heater core. The blower motor speed controls the volume of air flowing through the HVAC housing. The heater core cannot be repaired and must be replaced if restricted, leaking or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Installation Heater Core: Service and Repair Installation INSTALLATION 1. Carefully install the heater core (3) into the front of the HVAC housing. 2. Position the heater core tube bracket (2) onto the HVAC housing. 3. Install the two screws (1) that secure the heater core bracket to the HVAC housing. Tighten the screws to 1.1 Nm (10 in. lbs.). 4. If equipped with the dual zone heating-A/C system, install the linkage rod (4). 5. Install the foam seal onto the heater core tubes. NOTE: If the heater core is being replaced, flush the cooling system. 6. Install the HVAC housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Installation > Page 13518 Heater Core: Service and Repair Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. NOTE: Disassembly of the HVAC housing is not required to remove heater core. 1. Remove the HVAC housing. 2. Remove the foam seal from the heater core tubes. 3. If equipped with the dual zone heating-A/C system, remove the linkage rod (4) to gain access to the heater core (3). 4. Remove the two screws (1) that secure the heater core tube bracket (2) to the HVAC housing and remove the bracket. 5. Carefully pull the heater core out of the front of the HVAC housing. 6. Inspect all foam seals and replace as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > Operation High Pressure Safety Valve HVAC: Description and Operation Operation HIGH PRESSURE RELIEF VALVE The high pressure relief valve vents refrigerant from the A/C system when a discharge pressure of 3445 to 4135 kPa (500 to 600 psi) or above is reached. The high pressure relief valve closes with a minimum discharge pressure of 2756 kPa (400 psi) is reached. The high pressure relief valve vents only enough refrigerant to reduce the A/C system pressure, and then re-seats itself. The majority of the refrigerant is conserved in the A/C system. If the high pressure relief valve vents refrigerant, it does not mean the valve is inoperative. The high pressure relief valve is factory-calibrated and cannot be adjusted or repaired, and must not be removed or otherwise disturbed. The valve is only serviced as a part of the A/C compressor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > Operation > Page 13523 High Pressure Safety Valve HVAC: Description and Operation Description HIGH PRESSURE RELIEF VALVE A high pressure relief valve is located on the A/C compressor. This mechanical valve is designed to vent refrigerant from the A/C system to protect against damage to the A/C compressor and other A/C system components, caused by condenser air flow restriction or an overcharge of refrigerant. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service Precautions > Warning Hose/Line HVAC: Service Precautions Warning WARNING WARNING: The A/C system contains refrigerant under high pressure. Repairs should only be performed by qualified service personnel. Serious or fatal injury may result from improper service procedures. WARNING: Avoid breathing the refrigerant and refrigerant oil vapor or mist. Exposure may irritate the eyes, nose, and/or throat. Wear eye protection when servicing the A/C refrigerant system. Serious eye injury can result from direct contact with the refrigerant. If eye contact occurs, seek medical attention immediately. WARNING: Do not expose the refrigerant to open flame. Poisonous gas is created when refrigerant is burned. An electronic leak detector is recommended. Serious or fatal injury may result from improper service procedures. WARNING: If accidental A/C system discharge occurs, ventilate the work area before resuming service. Large amounts of refrigerant released in a closed work area will displace the oxygen and cause suffocation and serious or fatal injury. WARNING: The evaporation rate of R-134a refrigerant at average temperature and altitude is extremely high. As a result, anything that comes in contact with the refrigerant will freeze. Always protect the skin or delicate objects from direct contact with the refrigerant. WARNING: The R-134a service equipment or the vehicle refrigerant system should not be pressure tested or leak tested with compressed air. Some mixtures of air and R-134a have been shown to be combustible at elevated pressures. These mixtures are potentially dangerous, and may result in fire or explosion causing property damage and serious or fatal injury. WARNING: The engine cooling system is designed to develop internal pressures up to 145 kilo pascals (21 pounds per square inch). Do not remove or loosen the coolant pressure cap, cylinder block drain plugs, radiator drain, radiator hoses, heater hoses, or hose clamps while the engine cooling system is hot and under pressure. Allow the vehicle to cool for a minimum of 15 minutes before opening the cooling system for service. Failure to observe this warning can result in serious burns from the heated engine coolant. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service Precautions > Warning > Page 13528 Hose/Line HVAC: Service Precautions Caution CAUTION CAUTION: Never add R-12 to a refrigerant system designed to use R-134a. Do not use R-12 equipment or parts on an R-134a A/C system. These refrigerants are not compatible and damage to the A/C system will result. CAUTION: Never use R-12 refrigerant oil in an A/C system designed to use R-134a refrigerant oil. These refrigerant oils are not compatible and damage to the A/C system will result. CAUTION: The use of A/C system sealers may result in damage to A/C refrigerant recovery/evacuation/recharging equipment and/or A/C system. Many federal, state/provincial and local regulations prohibit the recharge of A/C systems with known leaks. DaimlerChrysler recommends the detection of A/C system leaks through the use of approved leak detectors and fluorescent leak detection dyes. Vehicles found with A/C system sealers should be treated as contaminated and replacement of the entire A/C refrigerant system is recommended. A/C systems found to be contaminated with A/C system sealers, A/C stop-leak products or seal conditioners voids the warranty for the A/C system. CAUTION: Recover the refrigerant before opening any fitting or connection. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant. CAUTION: If equipped, do not remove the secondary retention clip from any spring-lock coupler connection while the refrigerant system is under pressure. Recover the refrigerant before removing the secondary retention clip. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant. CAUTION: The internal parts of the A/C system will remain stable as long as moisture-free refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture or air can upset the chemical stability. This may cause operational troubles or even serious damage if present in more than very small quantities. Before disconnecting a component, clean the outside of the fittings thoroughly to prevent contamination from entering the refrigerant system. Keep service tools and the work area clean. Do not open the refrigerant system or uncap a replacement component until you are ready to service the system. Immediately after disconnecting a component from the refrigerant system, seal the open fittings with a cap or plug. This will prevent contamination from entering the A/C system. CAUTION: Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open a container of refrigerant oil until you are ready to use it. Replace the cap on the oil container immediately after using. Store refrigerant oil only in a clean, airtight, and moisture-free container. CAUTION: Do not overcharge the refrigerant system. Overcharging will cause excessive compressor head pressure and can cause compressor noise and A/C system failure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line Hose/Line HVAC: Description and Operation A/C Discharge Line DESCRIPTION The A/C discharge line is the refrigerant line that goes from the A/C compressor to the A/C condenser and has an integral fitting for the A/C pressure transducer. The A/C discharge line is made from light-weight aluminum tubing with braze-less and crimp type fittings and nylon tubes with rubber barrier hose. The A/C discharge line for the 5.9L and 6.7L diesel engines is serviced as an assembly with the A/C suction line. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C discharge line has no serviceable parts except the O-ring seals and gaskets. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C discharge line is removed. The A/C discharge line cannot be repaired and must be replaced if found to be leaking or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line > Page 13531 Hose/Line HVAC: Description and Operation A/C Liquid Line DESCRIPTION The A/C liquid line is the refrigerant line that carries refrigerant from the A/C condenser to the A/C evaporator. The A/C liquid line consists of two separate lines that connect to each other using a spring-lock type refrigerant line coupler. The A/C liquid line is made from light-weight aluminum tubing with braze-less and crimp type fittings and nylon tubes with rubber barrier hose. NOTE: A/C orifice tube size is different between gasoline and diesel engines. Be sure to use the correct A/C liquid line when replacement of the A/C orifice tube is required. The front section of the A/C liquid line includes the high-side service port and the rear section of the A/C liquid line includes the A/C fixed orifice tube. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C liquid line has no serviceable parts except for the O-ring seals and gaskets, high-side service port valve, cap and secondary retaining clip. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C liquid line is removed. The A/C liquid line cannot be repaired and must be replaced if found to be leaking or damaged, or if the fixed orifice tube is inoperative. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line > Page 13532 Hose/Line HVAC: Description and Operation A/C Suction Line DESCRIPTION The A/C suction line is the refrigerant line that goes from the A/C evaporator to the A/C compressor. The A/C suction line is made from light-weight aluminum tubing with braze-less and crimp type fittings and nylon tubes with rubber barrier hose. The A/C suction line for the 5.9L and 6.7L diesel engines is serviced as an assembly with the A/C discharge line. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C suction line has no serviceable parts except for the O-ring seals and the secondary retaining clip. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C suction line is removed. The A/C suction line cannot be repaired and must be replaced if found to be leaking or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line > Page 13533 Hose/Line HVAC: Description and Operation Plumbing Description DESCRIPTION The A/C refrigerant lines and hoses are used to carry the refrigerant between the various A/C system components. The refrigerant lines and hoses for the R-134a A/C system consist of a barrier-hose design with a nylon tube sandwiched between rubber layers. The nylon tube helps to contain the R-134a refrigerant, which has a small molecular structure. The ends of the refrigerant lines are made from lightweight aluminum and braze-less fittings. Any kinks or sharp bends in the refrigerant lines and hoses will reduce the capacity of the entire A/C system and can reduce the flow of refrigerant within the system. Operation OPERATION High pressures are produced in the refrigerant system when the A/C compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible refrigerant hoses at least once a year to make sure they are in good condition. The refrigerant lines and hoses are coupled to other A/C system components with block-type fittings. An O-ring seal, or a flat steel gasket with an integral O-ring (dual plane seal), is used to mate the refrigerant line fittings with A/C system components to ensure the integrity of the refrigerant system. The refrigerant lines and hoses cannot be repaired and must be replaced if leaking or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge Hose/Line HVAC: Service and Repair Line-A/C Discharge Removal 5.9L/6.7L DIESEL ENGINES WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. NOTE: The A/C discharge line for the 5.9L and the 6.7L diesel engine is serviced as an assembly with the A/C suction line. 1. Disconnect and isolate the negative battery cables. 2. Recover the refrigerant from the refrigerant system. 3. Remove the air filter housing cover. 4. Remove the secondary retaining clip (7) from the spring-lock coupler (1) that secures the A/C suction line (6) to the A/C accumulator (5). 5. Using the proper A/C line disconnect tool, disconnect the A/C suction line from the A/C accumulator and remove and discard the O-ring seals. 6. Install plugs in, or tape over the opened suction line fitting and the accumulator tube. 7. Disconnect the wire harness connector (5) from the A/C pressure transducer (4). 8. Remove the nut (2) that secures the A/C suction and discharge line assembly (3) to the A/C condenser (1). 9. Disconnect the A/C discharge line from the A/C condenser and remove and discard the O-ring seal and gasket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 13536 10. Remove the bolt (7) that secures the A/C suction and discharge line assembly to the A/C compressor (6). 11. Disconnect the A/C suction and discharge line assembly from the A/C compressor and remove and discard the O-ring seals and gasket. 12. Remove the A/C suction and discharge line assembly from the engine compartment. 13. Install plugs in, or tape over the opened refrigerant line fittings and the condenser and compressor ports. 14. If necessary, remove the A/C pressure transducer from the A/C discharge line. Installation 5.9L/6.7L DIESEL ENGINES CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: The A/C discharge line for the 5.9L and the 6.7L diesel engine is serviced as an assembly with the A/C suction line. 1. If removed, install the A/C pressure transducer (4) onto the A/C suction and discharge line assembly (3). 2. Remove the tape or plugs from the opened refrigerant line fittings and the condenser and compressor ports. 3. Position the A/C suction and discharge line assembly into the engine compartment. 4. Lubricate new O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Connect the A/C suction and discharge line assembly to the A/C condenser (1). 6. Install the nut (2) that secures the A/C discharge line to the A/C condenser. Tighten the nut to 23 Nm (17 ft. lbs.). 7. Connect the A/C suction and discharge line assembly to the A/C compressor (6). 8. Install the bolt (7) that secures the A/C suction and discharge line assembly to the A/C compressor. Tighten the bolt to 23 Nm (17 ft. lbs.). 9. Connect the wire harness connector (5) to the A/C pressure transducer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 13537 10. Remove the tape or plugs from the opened accumulator tube. 11. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the accumulator tube fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 12. Connect the A/C suction line (6) to the spring-lock coupler (1) on the A/C accumulator (5) and install the secondary retaining clip (7). 13. Install the air filter housing cover. 14. Reconnect the negative battery cables. 15. Evacuate the refrigerant system. 16. Adjust the refrigerant oil level. 17. Charge the refrigerant system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 13538 Hose/Line HVAC: Service and Repair Line-A/C Liquid Removal 5.9L/6.7L DIESEL ENGINES WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. NOTE: The A/C liquid line is serviced in two sections. FRONT SECTION 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system. 3. Remove the passenger side battery. 4. Remove the air seal from the right end of the A/C condenser (5) to gain access to the refrigerant line fittings. 5. Remove the nut (2) that secures the front section of the A/C liquid line (1) to the A/C condenser (3). 6. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring and gasket. 7. Disengage the A/C liquid line (1) from the three body retaining clips (2 and 3) located at the right front corner of the engine compartment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 13539 8. Remove the secondary retaining clip (2) from the spring-lock coupler that secures the front section of the A/C liquid line (1) to the rear section of the liquid line (3). 9. Using the proper A/C line disconnect tool (Special Tool Kit 7193 or equivalent), disconnect the front section of the A/C liquid line from the rear section of the liquid line and remove and discard the O-ring seals. 10. Install plugs in, or tape over the opened ends of the A/C liquid lines and the condenser port. 11. Remove the front section of the A/C liquid line from the engine compartment. REAR SECTION 12. Disconnect and isolate the negative battery cable. 13. Recover the refrigerant from the refrigerant system. 14. Remove the passenger side battery. 15. Disengage the rear section of the A/C liquid line (2) from the body retaining clip (5). 16. Remove the secondary retaining clip (1) from the spring-lock coupler that secures the front section of the A/C liquid line (6) to the rear section of the A/C liquid line. 17. Using the proper A/C line disconnect tool (Special Tool Kit 7193 or equivalent), disconnect the front section of the A/C liquid line from the rear section of the liquid line and remove and discard the O-ring seals. 18. Remove the secondary retaining clip (3) from the spring-lock coupler that secures the rear section of the A/C liquid line to the evaporator tube (4). 19. Using the proper A/C line disconnect tool (Special Tool Kit 7193 or equivalent), disconnect the A/C liquid line from the evaporator tube and remove and discard the O-ring seals. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 13540 20. Install plugs in, or tape over the opened ends of the A/C liquid lines and the evaporator tube, 21. Remove the rear section of the A/C liquid line from the engine compartment. Installation 5.9L/6.7L DIESEL ENGINES CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: The A/C liquid line is serviced in two sections. FRONT SECTION 1. Position the front section of the A/C liquid line (1) into the engine compartment. 2. Remove the tape or plugs from the opened ends of the A/C liquid lines and the condenser port. 3. Lubricate new O-ring seals with clean refrigerant oil and install them onto the front liquid line spring-lock coupler fitting. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the front section of the A/C liquid line to the rear section of the liquid line (3). 5. Install the secondary retaining clip (2) onto the spring-lock coupler that secures the front section of the A/C liquid line onto the rear section of the liquid line. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 13541 6. Engage the A/C liquid line (1) into the three body retaining clips (2 and 3) located at the right front corner of the engine compartment. 7. Lubricate a new O-ring with clean refrigerant oil and install it and a new gasket onto the front liquid line fitting. Use only the specified O-ring seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 8. Connect the front section of the A/C liquid line (2) to the condenser port. 9. Install the nut (1) that secures the A/C liquid line to the A/C condenser (3). Tighten the nut to 23 Nm (17 ft. lbs.). 10. Position the air seal over the right end of the A/C condenser and install the air seal retainers. 11. Install the passenger side battery tray. 12. Reconnect the negative battery cable(s). 13. Evacuate the refrigerant system. 14. Adjust the refrigerant oil level. 15. Charge the refrigerant system. REAR SECTION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 13542 16. Position the rear section of the A/C liquid line (2) into the engine compartment. 17. Remove the tape or plugs from the opened ends of the A/C liquid lines and the evaporator tube (4). 18. Lubricate new O-ring seals with clean refrigerant oil and install them onto the rear liquid line spring-lock coupler fitting. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 19. Connect the rear section of the A/C liquid line to the evaporator tube. 20. Install the secondary retaining clip (3) onto the spring-lock coupler that secures the rear section of the A/C liquid line onto the evaporator tube. 21. Engage the A/C liquid line into the body retaining clip (5). 22. Lubricate new O-ring seals with clean refrigerant oil and install them onto the front liquid line spring-lock coupler fitting. Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 23. Connect the rear section of the A/C liquid line (6) to the front section of the liquid line. 24. Install the secondary retaining clip (1) onto the spring-lock coupler that secures the front section of the A/C liquid line to the rear section of the liquid line. 25. Install the passenger side battery tray. 26. Reconnect the negative battery cables. 27. Evacuate the refrigerant system. 28. Adjust the refrigerant oil level. 29. Charge the refrigerant system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 13543 Hose/Line HVAC: Service and Repair Line-A/C Suction Removal 5.9L/6.7L DIESEL ENGINES WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. NOTE: The A/C suction line for the 5.9L and the 6.7L diesel engine is serviced as an assembly with the A/C discharge line. 1. Disconnect and isolate the negative battery cables. 2. Recover the refrigerant from the refrigerant system. 3. Remove the air filter housing cover. 4. Remove the secondary retaining clip (7) from the spring-lock coupler (1) that secures the A/C suction line (6) to the A/C accumulator (5). 5. Using the proper A/C line disconnect tool (Special Tool Kit 7193 or equivalent), disconnect the A/C suction line from the A/C accumulator and remove and discard the O-ring seals. 6. Install plugs in, or tape over the opened suction line fitting and the accumulator tube. 7. Disconnect the wire harness connector (5) from the A/C pressure transducer (4). 8. Remove the nut (2) that secures the A/C suction and discharge line assembly (3) to the A/C condenser (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 13544 9. Disconnect the A/C discharge line from the A/C condenser and remove and discard the O-ring seal and gasket. 10. Remove the bolt (7) that secures the A/C suction and discharge line assembly to the A/C compressor (6). 11. Disconnect the A/C suction and discharge line assembly from the A/C compressor and remove and discard the O-ring seals and gasket. 12. Remove the A/C suction and discharge line assembly from the engine compartment. 13. Install plugs in, or tape over the opened refrigerant line fittings and the condenser and compressor ports. 14. If necessary, remove the A/C pressure transducer from the A/C discharge line. Installation 5.9L/6.7L DIESEL ENGINES CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: The A/C suction line for the 5.9L and the 6.7L diesel engine is serviced as an assembly with the A/C discharge line. 1. If removed, install the A/C pressure transducer (4) onto the A/C suction and discharge line assembly (3). 2. Remove the tape or plugs from the opened refrigerant line fittings and the condenser and compressor ports. 3. Position the A/C suction and discharge line assembly into the engine compartment. 4. Lubricate new O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Connect the A/C suction and discharge line assembly to the A/C condenser (1). 6. Install the nut (2) that secures the A/C suction and discharge line assembly to the A/C condenser. Tighten the nut to 23 Nm (17 ft. lbs.). 7. Connect the A/C suction and discharge line assembly to the A/C compressor (6). 8. Install the bolt (7) that secures the A/C suction and discharge line assembly to the A/C compressor. Tighten the bolt to 23 Nm (17 ft. lbs.). 9. Connect the wire harness connector (5) to the A/C pressure transducer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Line-A/C Discharge > Page 13545 10. Remove the tape or plugs from the opened accumulator tube. 11. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the accumulator tube fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 12. Connect the A/C suction line (6) to the spring-lock coupler (1) on the A/C accumulator (5) and install the secondary retaining clip (7). 13. Install the air filter housing cove. 14. Reconnect the negative battery cables. 15. Evacuate the refrigerant system. 16. Adjust the refrigerant oil level. 17. Charge the refrigerant system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Description and Operation Housing Assembly HVAC: Description and Operation DESCRIPTION All models are equipped with a common HVAC housing assembly that combines A/C and heating capabilities into a single unit mounted within the passenger compartment. The HVAC housing assembly consists of the following: - HVAC housing - The HVAC housing consists of an upper housing (7) and a lower housing (10) that are attached together by screws and is mounted to the dash panel behind the instrument panel. The HVAC housing contains the heater core (9), A/C evaporator (15), blend-air and modeair doors, and has mounting provisions for the air-door actuators (3, 5, 6 and 8), floor distribution duct (4), blower motor (13), blower motor resistor, foam seals (12, 14 and 16) and the HVAC wire harness (11). - Air inlet housing - The air inlet housing (1) is mounted to the right end of the HVAC housing and contains the recirculation-air door and has mounting provisions for the recirculation door actuator (2). The heating-A/C system is a blend-air type system. The blend-air doors control the amount of conditioned air that is allowed to flow through, or around, the heater core. The dual zone heating A/C system uses two blend door actuators while the single zone system uses only one blend door actuator. The A/C system is designed for the use of a non-CFC, R-134a refrigerant and uses an A/C evaporator to cool and dehumidify the incoming air prior to blending it with the heated air. A temperature control determines the discharge air temperature by operating the blend door actuator(s), which moves the blend-air door(s). This allows an almost immediate control of the output air temperature of the system. The mode door actuator operates the mode-air doors which direct the flow of the conditioned air out the various air outlets, depending on the mode selected. The recirculation door actuator operates the recirculation-air door which closes off the fresh air intake and recirculates the air already inside the vehicle. The electric door actuators are connected to the vehicle electrical system by the HVAC wire harness. The blower motor controls the velocity of air flowing through the HVAC housing assembly by spinning the blower wheel within the HVAC housings at the selected speed by use of the blower motor resistor. The HVAC housing must be removed from the vehicle and disassembled for service of the heater core, A/C evaporator, evaporator temperature sensor, blend-air and mode-air doors. The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement Housing Assembly HVAC: Removal and Replacement Air Inlet Housing Removal and Installation AIR INLET HOUSING WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation Failure to follow these instructions may result in possible serious or fatal injury. WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: The air inlet housing does not need to be removed from the HVAC housing for service of the recirculation-air door only See: Air Door NOTE: The air inlet housing does not need to be removed from the HVAC housing for service of the recirculation-air door only See: Air Door 1. Disconnect and isolate the negative battery cable. 2. Drain the engine cooling system. 3. Disconnect the heater hoses from the heater core tubes. 4. Remove the Powertrain Control Module (PCM) to gain access to the two nuts (3) that secure the HVAC housing (1) to the engine compartment side of the dash panel (2) and remove the nuts See: Powertrain Management/Computers and Control Systems/Engine Control Module 5. Remove the instrument panel from the passenger compartment See: Body and Frame/Interior Moulding / Trim 6. Remove the bolt (5) that secures the HVAC housing (4) to the floor bracket (6). 7. Remove the two nuts (3 and 7) that secure the HVAC housing to the passenger compartment side of the dash panel (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 13551 8. Carefully pull the right side of the HVAC housing rearward to gain access to the front of the air inlet housing. 9. Remove the recirculation door actuator (1) from the air inlet housing (2) and disconnect the HVAC wire harness (4) from the actuator. 10. Remove the two screws (3) that secure the rear of the air inlet housing to the top of the HVAC housing (5). 11. Release the two retaining clips (1) that secure the front of the air inlet housing (2) to the top of the HVAC housing (3) and remove the air inlet housing. NOTE:If the foam seal on the air inlet housing is deformed or damaged, it must be replaced. 12. If required, disassemble the air inlet housing See: Overhaul Installation NOTE: If the foam seal on the air Inlet housing is deformed or damaged, it must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 13552 1. Position the air inlet housing (2) onto the top of the HVAC housing (3). 2. Engage the two retaining clips (1) that secure the front of the air inlet housing to the HVAC housing. 3. Install the two screws (3) that secure the rear of the air inlet housing (2) to the top of the HVAC housing (5). Tighten the screws to 1.1 N.m (10 in. lbs.). 4. Install the recirculation door actuator (1) onto the air inlet housing See: Air Door 5. Connect the HVAC wire harness (4) to the recirculation door actuator. 6. If removed, install the fresh air inlet (2) onto the dash panel (1). 7. Reposition the HVAC housing (4) to the passenger compartment with the mounting studs and the condensate drain tube in their proper locations in the dash panel. 8. Install the two nuts (3 and 7) that secure the HVAC housing to the passenger compartment side of the dash panel. Tighten the nuts to 6.8 N.m (60 in. lbs.). 9. Install the bolt (5) that secures the HVAC housing to the floor bracket (6). Tighten the bolt to 6.8 N.m (60 in.lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 13553 10. Install the instrument panel assembly See: Body and Frame/Interior Moulding / Trim 11. Install the two nuts (3) that secure the HVAC housing (1) to the engine compartment side of the dash panel (2). Tighten the nuts to 6.8 N.m (60 in. lbs.). 12. Install the Powertrain Control Module See: Powertrain Management/Computers and Control Systems/Engine Control Module 13. Connect the heater hoses to the heater core tubes. 14. Reconnect the negative battery cable. 15. Refill the engine cooling system See: Engine, Cooling and Exhaust/Cooling System 16. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection Air Inlet Housing Installation AIR INLET HOUSING NOTE: The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door. NOTE: If the foam seal on the air inlet housing is deformed or damaged, it must be replaced. 1. Position the air inlet housing (2) onto the top of the HVAC housing (3). 2. Engage the two retaining clips (1) that secure the front of the air inlet housing to the HVAC housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 13554 3. Install the two screws (3) that secure the rear of the air inlet housing (2) to the top of the HVAC housing (5). Tighten the screws to 1.1 Nm (10 in. lbs.). 4. Install the recirculation door actuator (1) onto the air inlet housing. 5. Connect the HVAC wire harness (4) to the recirculation door actuator. 6. Install the HVAC housing assembly. HVAC Housing - Removal HVAC HOUSING ASSEMBLY WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator, evaporator temperature sensor, mode-air and blend-air doors. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system. 3. Drain the engine cooling system. 4. Disconnect the A/C liquid line and the A/C accumulator from the A/C evaporator. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 13555 5. Disconnect the heater hoses from the heater core tubes. 6. Remove the powertrain control module (PCM) to gain access to the two nuts (3) that secure the HVAC housing (1) to the engine compartment side of the dash panel (2) and remove the nuts. 7. On Mega Cab models, remove the floor console duct. 8. Remove the instrument panel from the passenger compartment. 9. Remove the bolt (5) that secures the HVAC housing (4) to the floor bracket (6). 10. Remove the two nuts (3 and 7) that secure the HVAC housing to the passenger compartment side of the dash panel (1). 11. Pull the HVAC housing assembly rearward and remove the housing assembly from the passenger compartment. 12. If required, remove the fresh air inlet (2) from the dash panel (1). HVAC Housing - Installation HVAC HOUSING ASSEMBLY CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. NOTE: If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 13556 1. If removed, install the fresh air inlet (2) onto the dash panel (1). 2. Position the HVAC housing assembly (4) into the passenger compartment with the mounting studs and the condensate drain tube in their proper locations in the dash panel. 3. Install the two nuts (3 and 7) that secure the HVAC housing to the passenger compartment side of the dash panel. Tighten the nuts to 6.8 Nm (60 in. lbs.). 4. Install the bolt (5) that secures the HVAC housing to the floor bracket (6). Tighten the bolt to 6.8 Nm (60 in. lbs.). 5. Install the instrument panel assembly. 6. On Mega Cab models, install the floor console duct. 7. Install the two nuts (3) that secure the HVAC housing (1) to the engine compartment side of the dash panel (2). Tighten the nuts to 6.8 Nm (60 in. lbs.). 8. Install the powertrain control module (PCM). 9. Connect the heater hoses to the heater core tubes. 10. Connect the A/C liquid line and the A/C accumulator to the A/C evaporator. 11. Reconnect the negative battery cable. 12. If the heater core is being replaced, flush the cooling system. 13. Refill the engine cooling system. 14. Evacuate the refrigerant system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 13557 15. If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 16. Charge the refrigerant system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 13558 Housing Assembly HVAC: Overhaul Air Inlet Housing AIR INLET HOUSING NOTE: The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door. 1. Remove the air inlet housing (1) from the HVAC housing and place it on a workbench. 2. Remove the two foam insulators (2) from the air inlet housing. 3. To remove the recirculation-air door (1) from the air inlet housing (2), first carefully release the retaining tabs of actuator coupler (3) located on the inside surface of the air inlet housing and pull the actuator coupler out of the pivot shaft of the recirculation-air door. NOTE: If the seals on the air door is deformed or damaged, the air door must be replaced. 4. Remove the recirculation-air door from the air inlet housing. HVAC Housing HVAC HOUSING NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator, evaporator temperature sensor, mode-air and blend-air doors. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 13559 1. Remove the HVAC housing assembly and place it on a workbench. 2. Disconnect the HVAC wire harness connectors from the mode door actuators (1), blend door actuators (2) and the recirculation door actuator (3). 3. Remove the screws that secure the mode door actuators and the blend door actuators to the HVAC housing (5) and remove the actuators. 4. Remove the screws that secure the recirculation door actuator to the air inlet housing (4) and remove the actuator. 5. Disconnect the wire harness connectors (1 and 3) from the blower motor resistor (7) and the blower motor (2). 6. Remove the screws (4) that secure the blower motor to the HVAC housing (5) and remove the blower motor. 7. Remove the screws (6) that secure the blower motor resistor to the HVAC housing and remove the resistor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 13560 8. Disconnect the HVAC wire harness (1) from the evaporator temperature sensor (2) and remove the wiring harness and the sensor from the HVAC housing (4). 9. Remove the air inlet housing (3) from the HVAC housing. 10. Remove the two screws (1) that secure the panel/floor door outlet (2) to the top of the HVAC housing (4). NOTE: If the foam seal on the panel/floor door outlet is deformed or damaged, it must be replaced. 11. Release the two retaining tabs (3) that secure the panel/floor door outlet to the front of the HVAC housing and remove the door outlet. 12. Remove the three screws (1) that secure the panel/floor door assembly (2) to the top of the HVAC housing (3) and remove the door assembly. 13. To remove the panel/floor-air doors (1) from the panel/floor door plate (2), first carefully release the retaining tabs of actuator coupler (3) located Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 13561 on the inside surface of the door plate and pull the actuator coupler out of the pivot shaft of the panel/floor-air doors. NOTE: If the seals on the air doors is deformed or damaged, the air doors must be replaced. 14. Remove the panel/floor-air doors from the panel/floor door plate. NOTE: If the foam seal for the heater core tubes is deformed or damaged, the seal must be replaced. 15. Remove the foam seal from the heater core tubes. 16. If equipped with the dual zone heating-A/C system, remove the linkage rod (4) to gain access to the heater core (3). 17. Remove the two screws (1) that secure the heater core tube bracket (2) to the HVAC housing and remove the bracket. 18. Carefully pull the heater core out of the front of the HVAC housing. 19. Inspect all heater core foam seals and replace as required. 20. Remove the screws (3) that secure the floor distribution duct (1) to the bottom of the HVAC housing (2). 21. Remove the floor distribution duct from the HVAC housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 13562 22. Carefully disconnect the linkage rod (1) from the two blend-air door levers (2) located on the back of the HVAC housing (3). NOTE: If the foam seal for the evaporator condensate drain tube is deformed or damaged, the seal must be replaced. 23. Remove the foam seal (4) from the evaporator condensate drain tube (5). 24. Remove the fifteen screws (6) that secure the upper and lower HVAC housing halves together and separate the housing halves. 25. Release the three retaining tabs (1) that secure the lower blend door assembly (2) to the lower half of the HVAC housing (3) and remove the door assembly. 26. Release the three retaining tabs that secure the upper blend door assembly to the upper half of the HVAC housing and remove the door assembly. 27. To remove the blend-air doors (1) from each blend door plate (2), first carefully release the retaining tabs of actuator coupler (3) located on the Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 13563 inside surface of the door plate being serviced and pull the actuator coupler out of the pivot shaft of the blend-air doors. NOTE: If the seals on the air doors is deformed or damaged, the air doors must be replaced. 28. Remove the blend-air doors from the blend door plates. 29. Remove the defroster-air doors (1) from the lower half of the HVAC housing (2) by carefully release the retaining tabs of actuator coupler (3) located on the inside surface of the housing and pull the actuator coupler out of the pivot shaft of the defroster-air doors. NOTE: If the seals on the air doors is deformed or damaged, the air doors must be replaced. 30. Remove the defroster-air doors from the HVAC housing. NOTE: If the foam seal for the A/C evaporator tubes is deformed or damaged, the seal must be replaced. 31. Remove the foam seal (1) from around the tubes of the A/C evaporator (3). 32. Carefully lift the A/C evaporator out of the upper half of the HVAC housing (2). Air Inlet Housing AIR INLET HOUSING NOTE: The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 13564 NOTE: If the seals on the air door is deformed or damaged, the air door must be replaced. 1. Position the recirculation-air door (1) into the air inlet housing (2). CAUTION: Make sure that the recirculation-air door pivot shaft is properly seated in the pivot seat located in the air inlet housing. 2. Align the actuator coupler (3) with the recirculation-air door pivot shaft and install the coupler until the coupler retaining tabs are fully engaged to the air inlet housing. Be sure to install the coupler with the coupler arm located between the two stop tabs on the air inlet housing. 3. Install the two foam insulators (2) into the air inlet housing (1). 4. Install the air inlet housing onto the HVAC housing. HVAC Housing HVAC HOUSING CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. NOTE: If only the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 13565 1. Carefully install the A/C evaporator (3) into the upper half of the HVAC housing (2). 2. Install the foam seal (1) onto the tubes of the A/C evaporator. 3. Install the defroster-air doors (1) into the lower half of the HVAC housing (2). 4. Align the actuator coupler (3) with the defroster-air door pivot shaft and install the coupler into side of the HVAC housing. Be sure to install the coupler with the coupler arm located between the two stop tabs on the HVAC housing. 5. Install the blend-air doors (1) into each of the two blend door plates (2). 6. Align the actuator coupler (3) with each blend-air door pivot shaft and install the coupler into side of each blend door plate. Be sure to install each coupler with the coupler arm located between the two stop tabs on each blend door plate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 13566 7. Position the lower blend door assembly (2) into the lower half of the HVAC housing (3) and fully engage the three retaining tabs (1). 8. Position the upper blend door assembly into the upper half of the HVAC housing and fully engage the three retaining tabs. NOTE: Route the wire lead for the evaporator temperature sensor into the opening located on the upper half of the HVAC housing prior to installing the lower half of the HVAC housing. 9. Position the two halves of the HVAC housing together (3). 10. Install the fifteen screws (6) that secure the two housing halves together. Tighten the screws to 1.1 Nm (10 in. lbs.). 11. Install the foam seal (4) onto the evaporator condensate drain tube (5). 12. Connect the linkage rod (1) to the two blend-air door levers (2) located on the back of the HVAC housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 13567 13. Position the front floor distribution duct (1) to the bottom of the HVAC housing (2). 14. Install the screws (3) that secure the front floor distribution duct to the HVAC housing. Tighten the screws to 1.1 Nm (10 in. lbs.). 15. Carefully install the heater core (3) into the front of the HVAC housing. 16. Position the heater core tube bracket (2) onto the HVAC housing. 17. Install the two screws (1) that secure the heater core bracket to the HVAC housing. Tighten the screws to 1.1 Nm (10 in. lbs.). 18. If equipped with the dual zone heating-A/C system, install the linkage rod (4). 19. Install the foam seal onto the heater core tubes. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 13568 20. Install the panel/floor-air doors (1) into the panel/floor door plate (2). 21. Align the actuator coupler (3) with the panel/floor-air door pivot shaft and install the coupler into side of the panel/floor door plate. Be sure to install the coupler with the coupler arm located between the two stop tabs on the door plate. 22. Position the panel/floor door assembly (2) onto the top of the HVAC housing (3). NOTE: Install the two door springs onto the retaining screws prior to installation. 23. Install the three screws (2) that secure the door assembly to the HVAC housing. Tighten the screws to 1.1 Nm (10 in. lbs.). 24. Position the panel/floor door outlet (2) onto the top of the HVAC housing (3) and fully engage the two retaining tabs (3). 25. Install the two screws (1) that secure the panel/floor door outlet to the HVAC housing. Tighten the screws to 1.1 Nm (10 in. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 13569 26. Install the air inlet housing (3) onto the top of the HVAC housing (4). 27. Install the HVAC wire harness (1) onto the HVAC housing. Make sure the wires are routed through all wiring retainers. 28. Install the evaporator temperature sensor (2) into the opening in the top of the HVAC housing. Make sure the sensor is fully engage to the housing. 29. Connect the HVAC wire harness to the evaporator temperature sensor. 30. Position the blower motor resistor (7) and the blower motor (2) into the bottom of the HVAC housing (5). 31. Install the screws (4) that secure the blower motor to the HVAC housing. Tighten the screws to 1.7 Nm (15 in. lbs.). 32. Install the screws (6) that secure the blower motor resistor to the HVAC housing. Tighten the screws to 1.1 Nm (10 in. lbs.). 33. Connect the HVAC wire harness connectors (1 and 3) to blower motor resistor and the blower motor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 13570 34. Position the recirculation door actuator (3) onto the air inlet housing (4) and install the retaining screws. Tighten the screws to 1.1 Nm (10 in. lbs.) 35. Position the mode door actuators (1) and the blend door actuators (2) onto the HVAC housing (5) and install the retaining screws. Tighten the screws to 1.1 Nm (10 in. lbs.). 36. Connect the HVAC wire harness connectors to the actuators. 37. Install the HVAC housing. 38. If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications Refrigerant: Specifications R-134a Refrigerent Charge Capacity 1. 3.7/4.7/5.7 L ..................................................................................................................................... .......................................... 0.728 kg (1.604 lbs.) 2. 5.9/6.7 L .............................................................. ....................................................................................................................... 0.850 kg (1.873 lbs.) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Description and Operation > Description Refrigerant: Description and Operation Description DESCRIPTION The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a Chlorofluorocarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-flammable, clear, and colorless liquefied gas. Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Description and Operation > Description > Page 13576 Refrigerant: Description and Operation Operation OPERATION R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure, refrigerant oil sludge or poor A/C system performance. In addition, the polyalkylene glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a refrigerant system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the A/C compressor to identify that the A/C system is equipped with R-134a refrigerant. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Description and Operation > Page 13577 Refrigerant: Testing and Inspection REFRIGERANT SYSTEM LEAKS WARNING: R-134a service equipment or vehicle A/C system should not be pressure tested or leak tested with compressed air. Mixture of air and R-134a can be combustible at elevated pressures. These mixtures are potentially dangerous and may result in fire or explosion causing property damage and serious or fatal injury . Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Use only approved service equipment meeting SAE requirements to discharge an R-134a system. If accidental system discharge occurs, ventilate work area before resuming service. NOTE: If the A/C refrigerant system charge is empty or low, a leak in the A/C system is likely. Visually inspect all A/C lines, fittings and components for an oily residue. Oil residue can be an indicator of an A/C system leak location. NOTE: The only way to correctly determine if the refrigerant system is fully charged with R-134a is to completely evacuate and recharge the A/C system. Connect a suitable manifold gauge set and determine if the static A/C system pressure is above or below 345 kPa (50 psi). If less than 345 kPa (50 psi) , proceed to SYSTEM EMPTY. If greater than 345 kPa (50 psi), go to SYSTEM LOW. SYSTEM EMPTY 1. Evacuate the refrigerant system to the lowest degree of vacuum possible (approximately -88 kPa (- 26 in. Hg) or greater vacuum). Determine if the system holds a vacuum for 15 minutes. If vacuum is held, a leak is probably not present. If system will not maintain vacuum level, proceed to STEP 2. 2. Prepare and dispense 0.284 kilograms (10 ounces) of R-134a refrigerant into the evacuated refrigerant system and proceed to STEP 1 of the System Low procedure. SYSTEM LOW 3. Position the vehicle in a wind-free work area. This will aid in detecting small leaks. 4. Operate the heating-A/C system with the engine at idle under the following conditions for at least 5 minutes. - Doors or windows open - Transmission in Park or Neutral with the parking brake set (depending on application) - A/C-heater controls set to outside air, full cool, panel mode, high blower and with A/C compressor engaged CAUTION: A leak detector only designed for R-12 refrigerant will not detect leaks in an R-134a refrigerant system. 5. Shut the vehicle Off and wait 2-7 minutes. Then use an electronic leak detector that is designed to detect R-134a refrigerant and search for leaks. Fittings, lines or components that appear to be oily usually indicate a refrigerant leak. To inspect the A/C evaporator for leaks, insert the leak detector probe into the drain tube opening or an air outlet. A dye for R-134a is available to aid in leak detection. Use only DaimlerChrysler approved refrigerant dye. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery Refrigerant: Service and Repair Refrigerant System - Recovery REFRIGERANT SYSTEM RECOVERY WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions may result in serious or fatal injury. An R-134a refrigerant recovery/recycling/charging station (1) that meets SAE standard J2210 must be used to recover the refrigerant from the R-134a refrigerant system. Refer to the operating instructions supplied by the equipment manufacturer for the proper care and use of this equipment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery > Page 13580 Refrigerant: Service and Repair Refrigerant System - Evacuate REFRIGERANT SYSTEM EVACUATE NOTE: Special effort must be used to prevent moisture from entering the A/C system oil. Moisture in the oil is very difficult to remove and will cause a reliability problem with the A/C compressor. If an A/C compressor designed to use R-134a refrigerant is left open to the atmosphere for an extended period of time. It is recommended that the refrigerant oil be drained and replaced with new oil or a new A/C compressor be used. This will eliminate the possibility of contaminating the refrigerant system. If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be filled. Moisture and air mixed with the refrigerant will raise the compressor head pressure above acceptable operating levels. This will reduce the performance of the A/C system and damage the A/C compressor. Moisture will boil at near room temperature when exposed to vacuum. To evacuate the refrigerant system: NOTE: When connecting the service equipment coupling to the line fitting, verify that the valve of the coupling is fully closed. This will reduce the amount of effort required to make the connection. 1. Recover the refrigerant system. 2. Connect a suitable charging station, refrigerant recovery machine or a manifold gauge set with vacuum pump and refrigerant recovery equipment. 3. Open the suction and discharge valves and start the vacuum pump. The vacuum pump should run a minimum of 45 minutes prior to charge to eliminate all moisture in system. When the suction gauge reads to the lowest degree of vacuum possible (approximately -88 kPa (- 26 in. Hg) or greater) for 30 minutes, close all valves and turn off vacuum pump. If the system fails to reach specified vacuum, the refrigerant system likely has a leak that must be corrected. If the refrigerant system maintains specified vacuum for at least 30 minutes, start the vacuum pump, open the suction and discharge valves. Then allow the system to evacuate an additional 10 minutes. 4. Close all valves. Turn off and disconnect the vacuum pump. 5. Charge the refrigerant system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery > Page 13581 Refrigerant: Service and Repair Refrigerant System - Charge REFRIGERANT SYSTEM CHARGE WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions may result in serious or fatal injury. NOTE: The Underhood HVAC Specification Label contains the refrigerant fill specification of the vehicle being serviced. After all refrigerant system leaks have been repaired and the refrigerant system has been evacuated, a refrigerant charge can be injected into the system. An R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to charge the refrigerant system with R-134a refrigerant. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. CHARGING PROCEDURE CAUTION: A small amount of refrigerant oil is removed from the A/C system each time the refrigerant system is recovered and evacuated. Before charging the A/C system, you MUST replenish any oil lost during the recovery process. 1. Evacuate the refrigerant system. 2. Connect an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2210 to the refrigerant system. 3. Refer to A/C SPECIFICATIONS or the Underhood HVAC Specification Label for the proper amount of the refrigerant charge. 4. Measure the proper amount of refrigerant and heat it to 52° C (125° F) with the charging station. See the operating instructions supplied by the equipment manufacturer for proper use of this equipment. 5. Open both the suction and discharge valves, then open the charge valve to allow the heated refrigerant to flow into the system. 6. When the transfer of refrigerant has stopped, close both the suction and discharge valves. 7. If all of the refrigerant charge did not transfer from the dispensing device, open all of the windows in the vehicle and set the heating-A/C system controls so that the A/C compressor is engaged and the blower motor is operating at its lowest speed setting. Run the engine at a steady high idle ( about 1400 rpm). If the A/C compressor does not engage, test the compressor clutch circuits and repair as required. WARNING: Take care not to open the discharge (high pressure) valve at this time. Failure to follow this warning may result in serious or fatal injury. 8. Open the low-side valve to allow the remaining refrigerant to transfer to the refrigerant system. 9. Disconnect the charging station from the refrigerant system service ports. 10. Reinstall the caps onto the refrigerant system service ports. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Page 13582 Refrigerant: Tools and Equipment REFRIGERANT SYSTEM SERVICE EQUIPMENT WARNING: Eye protection must be worn when servicing an A/C refrigerant system. Turn all valves off (rotate clockwise) on the equipment being used before connecting or disconnecting service equipment from the refrigerant system. Failure to observe these warnings may result in personal injury or death. WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. When servicing the A/C system, an R-134a refrigerant recovery/recycling/charging station (1) that meets SAE standard J2210 must be used. Contact an automotive service equipment supplier for refrigerant recovery/recycling/charging equipment. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. A manifold gauge set (1) may be needed with some recovery/recycling/charging equipment. The manifold gauge set should have manual shut-off valves (2 and 6), or automatic back-flow valves located at the service port connector end of the manifold gauge set hoses (4 and 5). This will prevent refrigerant from being released into the atmosphere. MANIFOLD GAUGE SET CONNECTIONS CAUTION: Do not use an R-12 manifold gauge set on an R-134a system. The refrigerants are not compatible and system damage will result. RECOVERY/RECYCLING/EVACUATION/CHARGING HOSE- The center manifold hose (Yellow, or White, with Black stripe) (3) is used to Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Page 13583 recover, evacuate, and charge the refrigerant system. When the low or high pressure valves on the manifold gauge set are opened, the refrigerant in the system will escape through this hose. HIGH PRESSURE GAUGE HOSE- The high pressure hose (Red with Black stripe) (4) attaches to the high side service port. This service port is located on the A/C discharge line. On this model, an A/C pressure transducer is installed on the high side service port. A/C high-side pressures can be read using a scan tool. LOW PRESSURE GAUGE HOSE- The low pressure hose (Blue with Black stripe) (5) attaches to the low side service port. This service port is located either on the top of the A/C accumulator or on the A/C suction line near the accumulator, depending on engine application. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Description and Operation > Description Refrigerant Oil: Description and Operation Description DESCRIPTION The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, polyalkylene glycol (PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils, and should never be introduced to an R-134a refrigerant system. There are different PAG oils available, and each contains a different additive package. Use only refrigerant oil of the same type as recommended to service the refrigerant system (always refer to the specification tag included with the replacement A/C compressor or the A/C Underhood Specification Label located in the engine compartment). The Denso 10S17 A/C compressor used in this vehicle when equipped with the 3.7L, 4.7L or 5.7L engine is designed to use ND-8 PAG refrigerant oil. Use only this type of refrigerant oil when servicing the A/C compressor for these engines. The Visteon HS-18 A/C compressor used in this vehicle when equipped with 5.9L or 6.7L diesel engine is designed to use VC-46 PAG refrigerant oil. Use only this type of refrigerant oil when servicing this A/C compressor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Description and Operation > Description > Page 13589 Refrigerant Oil: Description and Operation Operation OPERATION After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause A/C compressor damage, and too much can reduce A/C system performance. PAG refrigerant oil is more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. After use, recap the oil container immediately to prevent moisture contamination. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Description and Operation > Page 13590 Refrigerant Oil: Service and Repair REFRIGERANT OIL LEVEL When an A/C system is assembled at the factory, all components except the A/C compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the A/C compressor is dispersed throughout the refrigerant system. The accumulator, A/C evaporator, A/C condenser and the A/C compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of refrigerant oil in the A/C system. This ensures proper lubrication of the A/C compressor. Too little oil will result in damage to the A/C compressor, while too much oil will reduce the cooling capacity of the A/C system and consequently result in higher discharge air temperatures. CAUTION: The refrigerant oil in the R-134a A/C system is unique depending on the A/C compressor used. Use only PAG oils that are designed to work with R-134a refrigerant and the A/C compressor in the vehicle. Always refer to the A/C Underhood Specification Label for the correct oil designation. The oil container should be kept tightly capped until it is ready for use and then tightly capped after use to prevent contamination from dirt and moisture. Refrigerant oil will quickly absorb any moisture it comes in contact with, therefore, special effort must be used to keep all R-134a system components moisture-free. Moisture in the refrigerant oil is very difficult to remove and will cause a reliability problem with the A/C compressor. NOTE: Most reclaim/recycling equipment will measure the lubricant being removed during recovery. This amount of lubricant should be added back into the system. Refer to the reclaim/recycling equipment manufacturers instructions. It will not be necessary to check the oil level in the A/C compressor or to add oil, unless there has been an oil loss. An oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting, a component, or a component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant oil must be added when an A/C accumulator, A/C evaporator or A/C condenser is replaced. See the Refrigerant Oil Capacities chart. The refrigerant oil level in a new A/C compressor must first be adjusted prior to compressor installation. COMPRESSOR OIL DRAIN PROCEDURE CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor. Failure to properly drain and measure the refrigerant oil from the A/C compressor can prevent the A/C system from operating as designed and cause serious compressor damage. The A/C compressor is filled with refrigerant oil from the factory. Use the following procedure to drain and measure refrigerant oil from the A/C compressor. 1. Drain all of the refrigerant oil from the old A/C compressor into a clean measured container. 2. Drain all of the refrigerant oil from the new A/C compressor into a clean measured container. 3. Refill the new A/C compressor with the same amount of refrigerant oil that was drained out of the old compressor. Use only clean refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Install the new A/C compressor onto the engine. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Component ID: 496 Component : TRANSDUCER-A/C PRESSURE Connector: Name : TRANSDUCER-A/C PRESSURE Color : BLACK # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 A/C PRESSURE GROUND C918 18BK/LB 2 A/C PRESSURE 5 VOLT SUPPLY C818 18LB/OR 3 A/C PRESSURE SIGNAL C18 18LB/BR 4-Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13594 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13595 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13596 Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13597 Connector: Name : TRANSDUCER-A/C PRESSURE Color : GRAY # of pins : 4 Qualifier : (6.7L/GAS) Pin Description Circuit 1 A/C PRESSURE GROUND C918 18BK/LB Pin Description Circuit 1 A/C PRESSURE GROUND C918 20BK/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13598 2 A/C PRESSURE 5 VOLT SUPPLY C818 18LB/OR 2 A/C PRESSURE 5 VOLT SUPPLY C818 20LB/OR 3 A/C PRESSURE SIGNAL C18 18LB/BR 3 A/C PRESSURE SIGNAL C18 20LB/BR 4-Component Location - 8 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13599 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13600 Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13601 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13602 Refrigerant Pressure Sensor / Switch: Diagrams Component ID: 496 Component : TRANSDUCER-A/C PRESSURE Connector: Name : TRANSDUCER-A/C PRESSURE Color : BLACK # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 A/C PRESSURE GROUND C918 18BK/LB 2 A/C PRESSURE 5 VOLT SUPPLY C818 18LB/OR 3 A/C PRESSURE SIGNAL C18 18LB/BR 4-Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13603 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13604 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13605 Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13606 Connector: Name : TRANSDUCER-A/C PRESSURE Color : GRAY # of pins : 4 Qualifier : (6.7L/GAS) Pin Description Circuit 1 A/C PRESSURE GROUND C918 18BK/LB Pin Description Circuit 1 A/C PRESSURE GROUND C918 20BK/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13607 2 A/C PRESSURE 5 VOLT SUPPLY C818 18LB/OR 2 A/C PRESSURE 5 VOLT SUPPLY C818 20LB/OR 3 A/C PRESSURE SIGNAL C18 18LB/BR 3 A/C PRESSURE SIGNAL C18 20LB/BR 4-Component Location - 8 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13608 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13609 Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13610 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Description Refrigerant Pressure Sensor / Switch: Description and Operation Description DESCRIPTION The A/C pressure transducer (1) is a switch that is installed on a fitting located on the A/C discharge line. An internally threaded fitting on the A/C pressure transducer connects it to the externally threaded Schrader-type fitting on the A/C discharge line. A rubber O-ring seals the connection between the A/C pressure transducer and the discharge line fitting. The A/C pressure transducer is connected to the vehicle electrical system by a molded plastic connector with three terminals. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Description > Page 13613 Refrigerant Pressure Sensor / Switch: Description and Operation Operation OPERATION The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the A/C discharge line and its internal resistance changes in response to the pressures it monitors. The powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) provides a five volt reference signal and a sensor ground to the A/C pressure transducer, then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure. The PCM/ECM is programmed to respond to this and other sensor inputs by controlling the operation of the A/C compressor clutch and the radiator cooling fan to help optimize A/C system performance and to protect the system components from damage. The PCM/ECM will disengage the A/C compressor clutch when high side pressure rises above 3172 kPa (460 psi) and re-engage the clutch when high side pressure drops below 1999 kPa (290 psi). The A/C pressure transducer will also disengage the A/C compressor clutch if the high side pressure drops below 193 kPa (28 psi) and will re-engage the clutch when the high side pressure rises above 234 kPa (34 psi). If the refrigerant pressure rises above 1655 kPa (240 psi), the PCM will actuate the cooling fan. The A/C pressure transducer signal to the PCM/ECM also prevents the A/C compressor clutch from engaging when ambient temperatures are below about 10° C (50° F) due to the pressure/temperature relationship of the refrigerant. A Schrader-type valve in the A/C discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the A/C system. The A/C pressure transducer is diagnosed using a scan tool. The A/C pressure transducer cannot be adjusted or repaired and must be replaced if found inoperative or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Removal Refrigerant Pressure Sensor / Switch: Service and Repair Removal REMOVAL NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer. NOTE: Typical A/C pressure transducer and refrigerant line shown. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector (1) from the A/C pressure transducer (2) located on the A/C discharge line (3). 3. Remove the A/C pressure transducer from the fitting on the A/C discharge line and remove and discard the O-ring seal. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Removal > Page 13616 Refrigerant Pressure Sensor / Switch: Service and Repair Installation INSTALLATION NOTE: Use only the specified O-ring as it is made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor. NOTE: Typical A/C pressure transducer and refrigerant line shown. 1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the discharge line fitting (3). 2. Install the A/C pressure transducer (2) onto the A/C discharge line. Tighten the A/C pressure transducer securely. 3. Connect the wire harness connector (1) to the A/C pressure transducer. 4. Reconnect the negative battery cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations Component ID: 387 Component : SENSOR-AMBIENT AIR TEMPERATURE Connector: Name : SENSOR-AMBIENT AIR TEMPERATURE Color : BLACK # of pins : 2 Pin Description Circuit 1 AAT SIGNAL G31 20VT/LG 2 AAT RETURN G930 20VT/TN Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 13621 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 13622 Ambient Temperature Sensor / Switch HVAC: Diagrams Component ID: 387 Component : SENSOR-AMBIENT AIR TEMPERATURE Connector: Name : SENSOR-AMBIENT AIR TEMPERATURE Color : BLACK # of pins : 2 Pin Description Circuit 1 AAT SIGNAL G31 20VT/LG 2 AAT RETURN G930 20VT/TN Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 13623 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Description Ambient Temperature Sensor / Switch HVAC: Description and Operation Description DESCRIPTION The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the left side of the radiator yoke, behind the radiator grille and in front of the engine compartment. The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Description > Page 13626 Ambient Temperature Sensor / Switch HVAC: Description and Operation Operation OPERATION The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent by the Totally Integrated Power Module (TIPM). The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the TIPM. Based upon the resistance in the sensor, the TIPM senses a specific voltage on the temperature sensor signal circuit. The TIPM then translates the voltage into a temperature reading that it sent over the Programmable Communications Interface (PCI) data bus circuit to other modules utilizing temperature information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Page 13627 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection AMBIENT TEMPERATURE SENSOR The temperature function is supported by the ambient temperature sensor, a wiring circuit, and the Totally Integrated Power Module (TIPM). When the sensor is exposed to temperatures above 60° C (140° F), or if the sensor circuit is shorted, 60° C (130/140° F) will appear in the display in place of the temperature. When the sensor is exposed to temperatures below - 40° C (- 40° F) or if the sensor circuit is open, - 40° C (- 40° F) will appear in the display for Compass Mini - Trip Computer (CMTC) equipped vehicles and - -° C (- -° F) will be displayed on Electronic Vehicle Information Center (EVIC) equipped vehicles. The ambient temperature sensor circuit can be diagnosed using the following Temperature System Test, and Sensor Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, test the Compass Mini - Trip Computer (CMTC) or Electronic Vehicle Information Center (EVIC) as applicable. TEMPERATURE SYSTEM TEST For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. NOTE: Temperature readings do not update immediately. Allow up to 60 seconds after the ignition switch is turned to the On position for readings to meet test specifications. 1. Turn the ignition switch to the Off position. Disconnect the wire harness connector from the ambient temperature sensor. 2. Turn the ignition switch to the On position. The CMTC display should now read - 40° C (- 40° F) or the EVIC display should now read - -° C (- ° F). If OK, go to STEP 3. If not OK, repair the shorted sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 3. Turn the ignition switch to the Off position. Taking care not to damage the wire terminals, connect a jumper wire between the two terminals in the body half of the ambient temperature sensor harness connector. 4. Turn the ignition switch to the On position. The CMTC or EVIC display should now read 60° C (130/140° F). If OK, go to STEP 5. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 5. Clear any Diagnostic Trouble Codes that may have been set while performing the test. Perform further diagnosis of the Compass Mini - Trip Computer (CMTC) or Electronic Vehicle Information Center (EVIC) as applicable. SENSOR TEST 1. Turn the ignition switch to the Off position. Disconnect the ambient temperature sensor harness connector. 2. Measure the resistance of the ambient temperature sensor. At - 40° C (- 40° F), the sensor resistance is 336 kilohms. At 55° C (130° F), the sensor resistance is 2.488 kilohms. The sensor resistance should read between these two values. If OK, perform further diagnosis of the Compass Mini - Trip Computer (CMTC) or Electronic Vehicle Information Center (EVIC) as applicable. If not OK, replace the inoperative ambient temperature sensor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Service and Repair > Removal Ambient Temperature Sensor / Switch HVAC: Service and Repair Removal REMOVAL 1. Open the hood. 2. Disconnect and isolate the battery negative cable. 3. Working on the underside of the hood, remove screw holding sensor to hood panel. 4. Disconnect the sensor electrical connector and remove sensor from vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Service and Repair > Removal > Page 13630 Ambient Temperature Sensor / Switch HVAC: Service and Repair Installation INSTALLATION 1. Connect the sensor electrical connector. 2. Working on the underside of the hood, install screw holding sensor to hood panel. 3. Connect the battery negative cable. 4. Close the hood. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations Component ID: 396 Component : SENSOR-EVAPORATOR TEMPERATURE Connector: Name : SENSOR-EVAPORATOR TEMPERATURE Color : NATURAL # of pins : 2 Pin Description Circuit 1 SENSOR GROUND C121 20DB/DG 2 EVAPORATOR TEMPERATURE SENSOR SIGNAL C21 20DB/LG Component Location - 40 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 13634 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 13635 Evaporator Temperature Sensor / Switch: Diagrams Component ID: 396 Component : SENSOR-EVAPORATOR TEMPERATURE Connector: Name : SENSOR-EVAPORATOR TEMPERATURE Color : NATURAL # of pins : 2 Pin Description Circuit 1 SENSOR GROUND C121 20DB/DG 2 EVAPORATOR TEMPERATURE SENSOR SIGNAL C21 20DB/LG Component Location - 40 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 13636 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Description Evaporator Temperature Sensor / Switch: Description and Operation Description DESCRIPTION NOTE: Cutaway of HVAC housing shown for clarity. The evaporator temperature sensor (1) is an electrical thermistor located within a molded plastic case that is inserted into the top of the HVAC housing (2) to measure the temperature of the conditioned air downstream of the A/C evaporator (3). Two terminals within the connector receptacle connect the sensor to the vehicle electrical system through a wire lead and connector of the HVAC wire harness. The external location of the evaporator temperature sensor allows the sensor to be removed or installed without disturbing the refrigerant in the A/C system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Description > Page 13639 Evaporator Temperature Sensor / Switch: Description and Operation Operation OPERATION The evaporator temperature sensor monitors the temperature of the conditioned air downstream of the A/C evaporator and supplies an input signal to the A/C-heater control. The A/C-heater control uses the evaporator temperature sensor input signal to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor will change its internal resistance in response to the temperatures it monitors and is connected to the A/C-heater control through sensor ground circuit and a 5-volt reference signal circuit. As the temperature of the A/C evaporator decreases, the internal resistance of the evaporator temperature sensor decreases. The A/C-heater control uses the monitored voltage reading as an indication of evaporator temperature. The A/C-heater control is programmed to respond to this input by requesting the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) to cycle the A/C compressor clutch as necessary to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor is diagnosed using a scan tool. The evaporator temperature sensor cannot be adjusted or repaired and must be replaced if found inoperative or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Removal Evaporator Temperature Sensor / Switch: Service and Repair Removal REMOVAL NOTE: Illustration shown with instrument panel removed for clarity. 1. Disconnect and isolate the negative battery cable. 2. Remove the glove box from the instrument panel. 3. Disconnect the HVAC wire harness (1) from the evaporator temperature sensor (2) located on the top of the HVAC housing (3). 4. Remove the evaporator temperature sensor from the HVAC housing by pulling the sensor upward while tipping it forward. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Removal > Page 13642 Evaporator Temperature Sensor / Switch: Service and Repair Installation INSTALLATION NOTE: Illustration shown with instrument panel removed for clarity. 1. Install the evaporator temperature sensor (2) into the opening in the top of the HVAC housing (3). Make sure the sensor is fully engage to the housing. 2. Connect the HVAC wire harness (1) to the evaporator temperature sensor. 3. Install the glove box. 4. Reconnect the negative battery cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Component ID: 496 Component : TRANSDUCER-A/C PRESSURE Connector: Name : TRANSDUCER-A/C PRESSURE Color : BLACK # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 A/C PRESSURE GROUND C918 18BK/LB 2 A/C PRESSURE 5 VOLT SUPPLY C818 18LB/OR 3 A/C PRESSURE SIGNAL C18 18LB/BR 4-Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13646 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13647 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13648 Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13649 Connector: Name : TRANSDUCER-A/C PRESSURE Color : GRAY # of pins : 4 Qualifier : (6.7L/GAS) Pin Description Circuit 1 A/C PRESSURE GROUND C918 18BK/LB Pin Description Circuit 1 A/C PRESSURE GROUND C918 20BK/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13650 2 A/C PRESSURE 5 VOLT SUPPLY C818 18LB/OR 2 A/C PRESSURE 5 VOLT SUPPLY C818 20LB/OR 3 A/C PRESSURE SIGNAL C18 18LB/BR 3 A/C PRESSURE SIGNAL C18 20LB/BR 4-Component Location - 8 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13651 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13652 Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13653 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13654 Refrigerant Pressure Sensor / Switch: Diagrams Component ID: 496 Component : TRANSDUCER-A/C PRESSURE Connector: Name : TRANSDUCER-A/C PRESSURE Color : BLACK # of pins : 4 Qualifier : (5.9L) Pin Description Circuit 1 A/C PRESSURE GROUND C918 18BK/LB 2 A/C PRESSURE 5 VOLT SUPPLY C818 18LB/OR 3 A/C PRESSURE SIGNAL C18 18LB/BR 4-Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13655 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13656 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13657 Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13658 Connector: Name : TRANSDUCER-A/C PRESSURE Color : GRAY # of pins : 4 Qualifier : (6.7L/GAS) Pin Description Circuit 1 A/C PRESSURE GROUND C918 18BK/LB Pin Description Circuit 1 A/C PRESSURE GROUND C918 20BK/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13659 2 A/C PRESSURE 5 VOLT SUPPLY C818 18LB/OR 2 A/C PRESSURE 5 VOLT SUPPLY C818 20LB/OR 3 A/C PRESSURE SIGNAL C18 18LB/BR 3 A/C PRESSURE SIGNAL C18 20LB/BR 4-Component Location - 8 Component Location - 9 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13660 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13661 Component Location - 16 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 13662 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Description Refrigerant Pressure Sensor / Switch: Description and Operation Description DESCRIPTION The A/C pressure transducer (1) is a switch that is installed on a fitting located on the A/C discharge line. An internally threaded fitting on the A/C pressure transducer connects it to the externally threaded Schrader-type fitting on the A/C discharge line. A rubber O-ring seals the connection between the A/C pressure transducer and the discharge line fitting. The A/C pressure transducer is connected to the vehicle electrical system by a molded plastic connector with three terminals. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Description > Page 13665 Refrigerant Pressure Sensor / Switch: Description and Operation Operation OPERATION The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the A/C discharge line and its internal resistance changes in response to the pressures it monitors. The powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) provides a five volt reference signal and a sensor ground to the A/C pressure transducer, then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure. The PCM/ECM is programmed to respond to this and other sensor inputs by controlling the operation of the A/C compressor clutch and the radiator cooling fan to help optimize A/C system performance and to protect the system components from damage. The PCM/ECM will disengage the A/C compressor clutch when high side pressure rises above 3172 kPa (460 psi) and re-engage the clutch when high side pressure drops below 1999 kPa (290 psi). The A/C pressure transducer will also disengage the A/C compressor clutch if the high side pressure drops below 193 kPa (28 psi) and will re-engage the clutch when the high side pressure rises above 234 kPa (34 psi). If the refrigerant pressure rises above 1655 kPa (240 psi), the PCM will actuate the cooling fan. The A/C pressure transducer signal to the PCM/ECM also prevents the A/C compressor clutch from engaging when ambient temperatures are below about 10° C (50° F) due to the pressure/temperature relationship of the refrigerant. A Schrader-type valve in the A/C discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the A/C system. The A/C pressure transducer is diagnosed using a scan tool. The A/C pressure transducer cannot be adjusted or repaired and must be replaced if found inoperative or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Removal Refrigerant Pressure Sensor / Switch: Service and Repair Removal REMOVAL NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer. NOTE: Typical A/C pressure transducer and refrigerant line shown. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector (1) from the A/C pressure transducer (2) located on the A/C discharge line (3). 3. Remove the A/C pressure transducer from the fitting on the A/C discharge line and remove and discard the O-ring seal. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Removal > Page 13668 Refrigerant Pressure Sensor / Switch: Service and Repair Installation INSTALLATION NOTE: Use only the specified O-ring as it is made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor. NOTE: Typical A/C pressure transducer and refrigerant line shown. 1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the discharge line fitting (3). 2. Install the A/C pressure transducer (2) onto the A/C discharge line. Tighten the A/C pressure transducer securely. 3. Connect the wire harness connector (1) to the A/C pressure transducer. 4. Reconnect the negative battery cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation Service Port HVAC: Description and Operation DESCRIPTION Two refrigerant system service ports are used to recover/recycle/evacuate/charge and test the A/C refrigerant system. Unique sizes are used on the service ports for the R-134a refrigerant system to ensure the system is not accidentally contaminated with R-12 refrigerant or service equipment used for R-12 refrigerant. The high side service port is located on the A/C discharge line. The A/C pressure transducer is mounted on the high side service port. The low side service port is located either on the top of the A/C accumulator or on the A/C suction line near the accumulator, depending on engine application. Both the high side and low side A/C service port valve cores are serviceable. Each of the service ports has a threaded plastic protective cap installed over it from the factory. After servicing the refrigerant system, always reinstall both of the service port caps. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Service and Repair > Removal Service Port HVAC: Service and Repair Removal REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions may result in serious or fatal injury. NOTE: Typical A/C service port shown. 1. Remove the protective cap (1) from the service port (2). 2. Recover the refrigerant from the refrigerant system. 3. Using a Schrader-type valve core tool, remove the valve core (3) from the service port. 4. Install a plug in, or tape over the opened service port(s). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Service and Repair > Removal > Page 13674 Service Port HVAC: Service and Repair Installation INSTALLATION NOTE: Typical A/C service port shown. 1. Lubricate the valve core (3) with clean refrigerant oil prior to installation. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 2. Remove the tape or plug from the service port (2). CAUTION: A valve core that is not fully seated in the A/C service port can result in damage to the valve during refrigerant system evacuation and charge. Such damage may result in a loss of system refrigerant while uncoupling the charge adapters. 3. Using a Schrader-type valve core tool, install and tighten the valve core into the service port(s). 4. Evacuate the refrigerant system. 5. Charge the refrigerant system. NOTE: The protective cap helps aid in service port sealing and helps protect the refrigerant system from contamination. Remember to always reinstall the protective cap onto the service port when refrigerant system service is complete. 6. Install the protective cap (1) onto the service port. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sound Pad / Under-Dash Noise Barrier > Component Information > Technical Service Bulletins > Recalls for Sound Pad / Under-Dash Noise Barrier: > H34 > Jan > 09 > Recall Dash Silencer Pad Support Bracket Installation Technical Service Bulletin # H34 Date: 090120 Recall - Dash Silencer Pad Support Bracket Installation January 2009 Dealer Service Instructions for: Safety Recall H34 Dash Silencer Pad Models 2007-2008 (DH) Dodge Truck (D1) Dodge Truck (DC) Dodge Truck (DM) Dodge Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ) built through November 5, 2007 (MDH 110523). IMPORTANT: Some of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The dash silencer pad on about 110,000 of the above vehicles may sag and contact the exhaust gas recirculation (EGR) cooler. This may cause the dash silencer to locally overheat and cause an underhood fire without warning. Repair All vehicles must have a dash silencer pad support bracket installed. Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sound Pad / Under-Dash Noise Barrier > Component Information > Technical Service Bulletins > Recalls for Sound Pad / Under-Dash Noise Barrier: > H34 > Jan > 09 > Recall Dash Silencer Pad Support Bracket Installation > Page 13683 Use the labor operation number and time allowance shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure 1. Open the hood. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sound Pad / Under-Dash Noise Barrier > Component Information > Technical Service Bulletins > Recalls for Sound Pad / Under-Dash Noise Barrier: > H34 > Jan > 09 > Recall Dash Silencer Pad Support Bracket Installation > Page 13684 2. Place the dash shield over the dash silencer pad on the dash panel as shown in Figure 1. Temporarily place a small block of wood between the EGR cooler and dash shield to hold it in place (Figure 1). 3. Using a cotter pin puller (Snap-on SGA173B or equivalent) pierce a hole through the dash silencer pad. Then use a circular motion to enlarge the hole in the dash silencer pad. Use the dash shield as a template (Figure 2). CAUTION: Failure to pierce a hole through the dash silencer pad will cause the dash silencer pad material to wrap around the screw during installation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sound Pad / Under-Dash Noise Barrier > Component Information > Technical Service Bulletins > Recalls for Sound Pad / Under-Dash Noise Barrier: > H34 > Jan > 09 > Recall Dash Silencer Pad Support Bracket Installation > Page 13685 4. Using one of the self-drilling screws provided and an air ratchet, install the screw located on the dash shield tab (Figure 3). 5. Using a cotter pin puller (Snap-on SGA173B or equivalent) pierce a hole through the dash silencer pad. Then use a circular motion to enlarge the hole in the dash silencer pad. Use the dash shield as a template (Figure 4). CAUTION: Failure to pierce a hole through the dash silencer pad will cause the dash silencer pad material to wrap around the screw during installation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sound Pad / Under-Dash Noise Barrier > Component Information > Technical Service Bulletins > Recalls for Sound Pad / Under-Dash Noise Barrier: > H34 > Jan > 09 > Recall Dash Silencer Pad Support Bracket Installation > Page 13686 6. Using a 1/8 inch (3 mm) drill bit, drill a hole into the dash panel using the dash shield as a template (Figure 5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sound Pad / Under-Dash Noise Barrier > Component Information > Technical Service Bulletins > Recalls for Sound Pad / Under-Dash Noise Barrier: > H34 > Jan > 09 > Recall Dash Silencer Pad Support Bracket Installation > Page 13687 7. Using an air ratchet, install the second dash shield retaining screw (Figure 6). 8. Remove the wood block installed in Step 2 (Figure 6). 9. Close the hood. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sound Pad / Under-Dash Noise Barrier > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sound Pad / Under-Dash Noise Barrier: > H34 > Jan > 09 > Recall - Dash Silencer Pad Support Bracket Installation Technical Service Bulletin # H34 Date: 090120 Recall - Dash Silencer Pad Support Bracket Installation January 2009 Dealer Service Instructions for: Safety Recall H34 Dash Silencer Pad Models 2007-2008 (DH) Dodge Truck (D1) Dodge Truck (DC) Dodge Truck (DM) Dodge Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ) built through November 5, 2007 (MDH 110523). IMPORTANT: Some of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The dash silencer pad on about 110,000 of the above vehicles may sag and contact the exhaust gas recirculation (EGR) cooler. This may cause the dash silencer to locally overheat and cause an underhood fire without warning. Repair All vehicles must have a dash silencer pad support bracket installed. Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sound Pad / Under-Dash Noise Barrier > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sound Pad / Under-Dash Noise Barrier: > H34 > Jan > 09 > Recall - Dash Silencer Pad Support Bracket Installation > Page 13693 Use the labor operation number and time allowance shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Service Procedure 1. Open the hood. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sound Pad / Under-Dash Noise Barrier > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sound Pad / Under-Dash Noise Barrier: > H34 > Jan > 09 > Recall - Dash Silencer Pad Support Bracket Installation > Page 13694 2. Place the dash shield over the dash silencer pad on the dash panel as shown in Figure 1. Temporarily place a small block of wood between the EGR cooler and dash shield to hold it in place (Figure 1). 3. Using a cotter pin puller (Snap-on SGA173B or equivalent) pierce a hole through the dash silencer pad. Then use a circular motion to enlarge the hole in the dash silencer pad. Use the dash shield as a template (Figure 2). CAUTION: Failure to pierce a hole through the dash silencer pad will cause the dash silencer pad material to wrap around the screw during installation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sound Pad / Under-Dash Noise Barrier > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sound Pad / Under-Dash Noise Barrier: > H34 > Jan > 09 > Recall - Dash Silencer Pad Support Bracket Installation > Page 13695 4. Using one of the self-drilling screws provided and an air ratchet, install the screw located on the dash shield tab (Figure 3). 5. Using a cotter pin puller (Snap-on SGA173B or equivalent) pierce a hole through the dash silencer pad. Then use a circular motion to enlarge the hole in the dash silencer pad. Use the dash shield as a template (Figure 4). CAUTION: Failure to pierce a hole through the dash silencer pad will cause the dash silencer pad material to wrap around the screw during installation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sound Pad / Under-Dash Noise Barrier > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sound Pad / Under-Dash Noise Barrier: > H34 > Jan > 09 > Recall - Dash Silencer Pad Support Bracket Installation > Page 13696 6. Using a 1/8 inch (3 mm) drill bit, drill a hole into the dash panel using the dash shield as a template (Figure 5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Heating and Air Conditioning > Sound Pad / Under-Dash Noise Barrier > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sound Pad / Under-Dash Noise Barrier: > H34 > Jan > 09 > Recall - Dash Silencer Pad Support Bracket Installation > Page 13697 7. Using an air ratchet, install the second dash shield retaining screw (Figure 6). 8. Remove the wood block installed in Step 2 (Figure 6). 9. Close the hood. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair Repairs and Inspections Required After a Collision: Service and Repair SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT Any vehicle which is to be returned to use following a supplemental restraint deployment, must have the deployed restraints replaced. In addition, if the driver airbag has been deployed, the clockspring must be replaced. If the passenger airbag is deployed, the passenger airbag door must be replaced. The seat belt tensioners are deployed by the same signal that deploys the driver and passenger airbags and must also be replaced if either front airbag has been deployed. If a side curtain airbag has been deployed, the complete airbag unit, the headliner, as well as the upper A, B, and C-pillar trim must be replaced. These components are not intended for reuse and will be damaged or weakened as a result of a supplemental restraint deployment, which may or may not be obvious during a visual inspection. On vehicles with an optional sunroof, the sunroof drain tubes and hoses must be closely inspected following a side curtain airbag deployment. It is also critical that the mounting surfaces and mounting brackets for the Occupant Restraint Controller (ORC), side impact sensors, and front impact sensors be closely inspected and restored to their original conditions following any vehicle impact damage. Because the ORC and each front and side impact sensor are used by the supplemental restraint system to monitor or confirm the direction and severity of a vehicle impact, improper orientation or insecure fastening of these components may cause airbags not to deploy when required, or to deploy when not required. All other vehicle components should be closely inspected following any supplemental restraint deployment, but are to be replaced only as required by the extent of the visible damage incurred. AIRBAG SQUIB STATUS Multistage airbags with multiple initiators (squibs) must be checked to determine that all squibs were used during the deployment event. The driver and passenger airbags in this vehicle are deployed by electrical signals generated by the Occupant Restraint Controller (ORC) through the driver or passenger squib 1 and squib 2 circuits to the two initiators in the airbag inflators. Typically, both initiators are used and all potentially hazardous chemicals are burned during an airbag deployment event. However, it is possible for only one initiator to be used due to an airbag system fault; therefore, it is always necessary to confirm that both initiators have been used in order to avoid the improper handling or disposal of potentially live pyrotechnic or hazardous materials. The following procedure should be performed using a diagnostic scan tool to verify the status of both airbag squibs before either deployed airbag is removed from the vehicle for disposal. CAUTION: Deployed front airbags having two initiators (squibs) in the airbag inflator may or may not have live pyrotechnic material within the inflator. Do not dispose of these airbags unless you are certain of complete deployment. Refer to the Hazardous Substance Control System for proper disposal procedures. Dispose of all non-deployed and deployed airbags and seat belt tensioners in a manner consistent with state, provincial, local, and federal regulations. 1. Be certain that the diagnostic scan tool contains the latest version of the proper diagnostic software. Connect the scan tool to the 16-way Data Link Connector (DLC). The DLC is located on the driver side lower edge of the instrument panel, outboard of the steering column. 2. Turn the ignition switch to the ON position. 3. Using the scan tool, read and record the active (current) Diagnostic Trouble Code (DTC) data. Using the active DTC information, refer to the Airbag Squib Status table to determine the status of both driver and passenger airbag squibs. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Page 13702 NOTE: If none of the Driver or Passenger Squib 1 or 2 open are active codes, the status of the airbag squibs is unknown. In this case the airbag should be handled and disposed of as if the squibs were both live. CLEANUP PROCEDURE Following a supplemental restraint deployment, the vehicle interior will contain a powdery residue. This residue consists primarily of harmless particulate by-products of the small pyrotechnic charge that initiates the propellant used to deploy a supplemental restraint. However, this residue may also contain traces of sodium hydroxide powder, a chemical by-product of the propellant material that is used to generate the inert gas that inflates the airbag. Since sodium hydroxide powder can irritate the skin, eyes, nose, or throat, be certain to wear safety glasses, rubber gloves, and a long-sleeved shirt during cleanup. WARNING: To avoid serious or fatal injury, if you experience skin irritation during cleanup, run cool water over the affected area. Also, if you experience irritation of the nose or throat, exit the vehicle for fresh air until the irritation ceases. If irritation continues, see a physician. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Page 13703 1. Begin the cleanup by using a vacuum cleaner to remove any residual powder from the vehicle interior. Clean from outside the vehicle and work your way inside, so that you avoid kneeling or sitting on a non-cleaned area. 2. Be certain to vacuum the heater and air conditioning outlets as well. Run the heater and air conditioner blower on the lowest speed setting and vacuum any powder expelled from the outlets. CAUTION: Deployed front airbags having two initiators (squibs) in the airbag inflator may or may not have live pyrotechnic material within the inflator. Do not dispose of these airbags unless you are certain of complete deployment. Refer to AIRBAG SQUIB STATUS. All damaged, ineffective, or non-deployed supplemental restraints which are replaced on vehicles are to be handled and disposed of properly. If an airbag or seat belt tensioner unit is ineffective or damaged and non-deployed, refer to the Hazardous Substance Control System for proper disposal. Be certain to dispose of all non-deployed and deployed supplemental restraints in a manner consistent with state, provincial, local and federal regulations. 3. Next, remove the deployed supplemental restraints from the vehicle. 4. You may need to vacuum the interior of the vehicle a second time to recover all of the powder. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation Air Bag(s) Arming and Disarming: Technical Service Bulletins Air Bag System - Passenger Air Bag Deactivation NUMBER: 08-001-07 REV. B GROUP: Electrical DATE: May 16, 2007 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED. THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION. DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION. SUBJECT: Passenger Air Bag Deactivation MODELS: 2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 0300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakoka 2006 - 2007 (DR) Ram Truck 2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 13709 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet. NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States. PARTS REQUIRED: POLICY: Information Only Disclaimer: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 13710 This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation Air Bag: Technical Service Bulletins Air Bag System - Passenger Air Bag Deactivation NUMBER: 08-001-07 REV. B GROUP: Electrical DATE: May 16, 2007 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED. THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION. DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION. SUBJECT: Passenger Air Bag Deactivation MODELS: 2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 0300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakoka 2006 - 2007 (DR) Ram Truck 2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 13715 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet. NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States. PARTS REQUIRED: POLICY: Information Only Disclaimer: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 13716 This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Side Curtain-Right Air Bag: Locations Airbag-Side Curtain-Right Component ID: 12 Component : AIRBAG-SIDE CURTAIN-RIGHT Connector: Name : AIRBAG-SIDE CURTAIN-RIGHT Color : YELLOW # of pins : 2 Pin Description Circuit 1 RIGHT CURTAIN SQUIB 1 LINE 1 R4 20OR/LB 2 RIGHT CURTAIN SQUIB 1 LINE 2 R2 20WT/LB Component Location - 61 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Side Curtain-Right > Page 13719 Component Location - 64 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Side Curtain-Right > Page 13720 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Side Curtain-Right > Page 13721 Air Bag: Locations Sensor-Front Impact-Right Component ID: 403 Component : SENSOR-FRONT IMPACT-RIGHT Connector: Name : SENSOR-FRONT IMPACT-RIGHT Color : YELLOW # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 RIGHT FRONT IMPACT SENSOR GROUND R82 20WT/LB 2 RIGHT FRONT IMPACT SENSOR SIGNAL R80 20VT/LB Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Side Curtain-Right > Page 13722 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Side Curtain-Right > Page 13723 Air Bag: Locations Airbag-Driver Squib 1 Component ID: 8 Component : AIRBAG-DRIVER SQUIB 1 Connector: Name : AIRBAG-DRIVER SQUIB 1 Color : BLACK # of pins : 0 Pin Description Circuit 1 DRIVER SQUIB 1 LINE 1 R43 20LG/LB 2 DRIVER SQUIB 1 LINE 2 R45 20LG/OR Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Side Curtain-Right > Page 13724 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Side Curtain-Right > Page 13725 Air Bag: Locations Airbag-Driver Squib 2 Component ID: 9 Component : AIRBAG-DRIVER SQUIB 2 Connector: Name : AIRBAG-DRIVER SQUIB 2 Color : BROWN # of pins : 0 Gender : MALE Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R61 20LG/VT 2 DRIVER SQUIB 2 LINE 2 R63 20LG/WT Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Side Curtain-Right > Page 13726 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Side Curtain-Right > Page 13727 Air Bag: Locations Airbag-Side Curtain-Right Component ID: 12 Component : AIRBAG-SIDE CURTAIN-RIGHT Connector: Name : AIRBAG-SIDE CURTAIN-RIGHT Color : YELLOW # of pins : 2 Pin Description Circuit 1 RIGHT CURTAIN SQUIB 1 LINE 1 R4 20OR/LB 2 RIGHT CURTAIN SQUIB 1 LINE 2 R2 20WT/LB Component Location - 61 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Side Curtain-Right > Page 13728 Component Location - 64 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Side Curtain-Right > Page 13729 Sensor-Front Impact-Right Component ID: 403 Component : SENSOR-FRONT IMPACT-RIGHT Connector: Name : SENSOR-FRONT IMPACT-RIGHT Color : YELLOW # of pins : 2 Qualifier : (GAS) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Side Curtain-Right > Page 13730 Pin Description Circuit 1 RIGHT FRONT IMPACT SENSOR GROUND R82 20WT/LB 2 RIGHT FRONT IMPACT SENSOR SIGNAL R80 20VT/LB Component Location - 29 Airbag-Driver Squib 1 Component ID: 8 Component : AIRBAG-DRIVER SQUIB 1 Connector: Name : AIRBAG-DRIVER SQUIB 1 Color : BLACK # of pins : 0 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Side Curtain-Right > Page 13731 Pin Description Circuit 1 DRIVER SQUIB 1 LINE 1 R43 20LG/LB 2 DRIVER SQUIB 1 LINE 2 R45 20LG/OR Component Location - 43 Airbag-Driver Squib 2 Component ID: 9 Component : AIRBAG-DRIVER SQUIB 2 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Side Curtain-Right > Page 13732 Connector: Name : AIRBAG-DRIVER SQUIB 2 Color : BROWN # of pins : 0 Gender : MALE Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R61 20LG/VT 2 DRIVER SQUIB 2 LINE 2 R63 20LG/WT Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Side Curtain-Right > Page 13733 Airbag-Passenger Squib Component ID: 10 Component : AIRBAG-PASSENGER SQUIB Connector: Name : AIRBAG-PASSENGER SQUIB Color : YELLOW # of pins : 4 Pin Description Circuit Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Side Curtain-Right > Page 13734 1 PASSENGER SQUIB 1 LINE 2 R44 20LB/OR 2 PASSENGER SQUIB 1 LINE 1 R42 20LB/BR 3 PASSENGER SQUIB 2 LINE 1 R64 20LB/WT 4 PASSENGER SQUIB 2 LINE 2 R62 20LB/VT Component Location - 46 Airbag-Side Curtain-Left Component ID: 11 Component : AIRBAG-SIDE CURTAIN-LEFT Connector: Name : AIRBAG-SIDE CURTAIN-LEFT Color : YELLOW # of pins : 2 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Side Curtain-Right > Page 13735 Pin Description Circuit 1 LEFT CURTAIN SQUIB 1 LINE 1 R3 20LB/OR 2 LEFT CURTAIN SQUIB 1 LINE 2 R1 20LB/WT Component Location - 58 Component Location - 63 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Airbag-Side Curtain-Right > Page 13736 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Side Curtain-Right Air Bag: Diagrams Airbag-Side Curtain-Right Component ID: 12 Component : AIRBAG-SIDE CURTAIN-RIGHT Connector: Name : AIRBAG-SIDE CURTAIN-RIGHT Color : YELLOW # of pins : 2 Pin Description Circuit 1 RIGHT CURTAIN SQUIB 1 LINE 1 R4 20OR/LB 2 RIGHT CURTAIN SQUIB 1 LINE 2 R2 20WT/LB Component Location - 61 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Side Curtain-Right > Page 13739 Component Location - 64 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Side Curtain-Right > Page 13740 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Side Curtain-Right > Page 13741 Air Bag: Diagrams Sensor-Front Impact-Right Component ID: 403 Component : SENSOR-FRONT IMPACT-RIGHT Connector: Name : SENSOR-FRONT IMPACT-RIGHT Color : YELLOW # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 RIGHT FRONT IMPACT SENSOR GROUND R82 20WT/LB 2 RIGHT FRONT IMPACT SENSOR SIGNAL R80 20VT/LB Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Side Curtain-Right > Page 13742 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Side Curtain-Right > Page 13743 Air Bag: Diagrams Airbag-Driver Squib 1 Component ID: 8 Component : AIRBAG-DRIVER SQUIB 1 Connector: Name : AIRBAG-DRIVER SQUIB 1 Color : BLACK # of pins : 0 Pin Description Circuit 1 DRIVER SQUIB 1 LINE 1 R43 20LG/LB 2 DRIVER SQUIB 1 LINE 2 R45 20LG/OR Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Side Curtain-Right > Page 13744 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Side Curtain-Right > Page 13745 Air Bag: Diagrams Airbag-Driver Squib 2 Component ID: 9 Component : AIRBAG-DRIVER SQUIB 2 Connector: Name : AIRBAG-DRIVER SQUIB 2 Color : BROWN # of pins : 0 Gender : MALE Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R61 20LG/VT 2 DRIVER SQUIB 2 LINE 2 R63 20LG/WT Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Side Curtain-Right > Page 13746 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Side Curtain-Right > Page 13747 Air Bag: Diagrams Airbag-Side Curtain-Right Component ID: 12 Component : AIRBAG-SIDE CURTAIN-RIGHT Connector: Name : AIRBAG-SIDE CURTAIN-RIGHT Color : YELLOW # of pins : 2 Pin Description Circuit 1 RIGHT CURTAIN SQUIB 1 LINE 1 R4 20OR/LB 2 RIGHT CURTAIN SQUIB 1 LINE 2 R2 20WT/LB Component Location - 61 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Side Curtain-Right > Page 13748 Component Location - 64 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Side Curtain-Right > Page 13749 Sensor-Front Impact-Right Component ID: 403 Component : SENSOR-FRONT IMPACT-RIGHT Connector: Name : SENSOR-FRONT IMPACT-RIGHT Color : YELLOW # of pins : 2 Qualifier : (GAS) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Side Curtain-Right > Page 13750 Pin Description Circuit 1 RIGHT FRONT IMPACT SENSOR GROUND R82 20WT/LB 2 RIGHT FRONT IMPACT SENSOR SIGNAL R80 20VT/LB Component Location - 29 Airbag-Driver Squib 1 Component ID: 8 Component : AIRBAG-DRIVER SQUIB 1 Connector: Name : AIRBAG-DRIVER SQUIB 1 Color : BLACK # of pins : 0 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Side Curtain-Right > Page 13751 Pin Description Circuit 1 DRIVER SQUIB 1 LINE 1 R43 20LG/LB 2 DRIVER SQUIB 1 LINE 2 R45 20LG/OR Component Location - 43 Airbag-Driver Squib 2 Component ID: 9 Component : AIRBAG-DRIVER SQUIB 2 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Side Curtain-Right > Page 13752 Connector: Name : AIRBAG-DRIVER SQUIB 2 Color : BROWN # of pins : 0 Gender : MALE Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R61 20LG/VT 2 DRIVER SQUIB 2 LINE 2 R63 20LG/WT Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Side Curtain-Right > Page 13753 Airbag-Passenger Squib Component ID: 10 Component : AIRBAG-PASSENGER SQUIB Connector: Name : AIRBAG-PASSENGER SQUIB Color : YELLOW # of pins : 4 Pin Description Circuit Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Side Curtain-Right > Page 13754 1 PASSENGER SQUIB 1 LINE 2 R44 20LB/OR 2 PASSENGER SQUIB 1 LINE 1 R42 20LB/BR 3 PASSENGER SQUIB 2 LINE 1 R64 20LB/WT 4 PASSENGER SQUIB 2 LINE 2 R62 20LB/VT Component Location - 46 Airbag-Side Curtain-Left Component ID: 11 Component : AIRBAG-SIDE CURTAIN-LEFT Connector: Name : AIRBAG-SIDE CURTAIN-LEFT Color : YELLOW # of pins : 2 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Side Curtain-Right > Page 13755 Pin Description Circuit 1 LEFT CURTAIN SQUIB 1 LINE 1 R3 20LB/OR 2 LEFT CURTAIN SQUIB 1 LINE 2 R1 20LB/WT Component Location - 58 Component Location - 63 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Airbag-Side Curtain-Right > Page 13756 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Air Bag-Side Curtain Air Bag: Description and Operation Air Bag-Side Curtain Description DESCRIPTION Optional side curtain airbags are available for this vehicle when it is also equipped with dual front airbags. These airbags are passive, inflatable, Supplemental Restraint System (SRS) components, and vehicles with this equipment can be readily identified by a molded identification trim button with the SRS - AIRBAG logo located on the headliner above each A-pillar (standard cab), or above each B-pillar (quad cab and mega cab). This system is designed to reduce injuries to the vehicle occupants in the event of a side impact collision. Vehicles equipped with side curtain airbags have two individually controlled curtain airbag units. These airbag units are concealed and mounted above the headliner where they are each secured to one of the roof side rails (5). Each folded airbag cushion is contained within a fabric wrap (8) that extends along the roof rail from the A-pillar (6) at the front of the vehicle to the pillar at the rear of the vehicle. The channel is initially secured during installation with plastic push-in fasteners to the roof rail. A long tether (7) extends down the A-pillar from the front of the airbag cushion, where it is retained to the pillar with plastic push-in routing clips and it is secured to the base of the A-pillar near the belt line with a screw. Mega cab vehicles also have a rear tether that is retained with plastic push-in routing clips and secured to the C-pillar near the back of the cab with a screw. The hybrid-type inflator (3) for each airbag is secured to the roof rail at the rear of the airbag unit behind the B-pillar (standard cab) or C-pillar (quad cab and mega cab), and is connected to the airbag cushion by a long tubular manifold (4). The entire assembly is secured to several spring nuts spaced along the inside of the roof rail with screws. A two-wire take out and connector of the body wire harness with a keyed and latched connector insulator (1) on the B-pillar (standard cab) or C-pillar (quad cab and mega cab) is connected directly to the connector receptacle of the initiator near the back of the airbag inflator. The body wire harness connects each curtain airbag unit to the Occupant Restraint Controller (ORC). The side curtain airbag unit cannot be adjusted or repaired and must be replaced if deployed, ineffective, or in any way damaged. Once a side curtain airbag has been deployed, the complete airbag unit, the headliner, the upper A, B, and C-pillar trim, and all other visibly damaged components must be replaced. Operation Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Air Bag-Side Curtain > Page 13759 OPERATION Each side curtain airbag is deployed individually by an electrical signal generated by the Occupant Restraint Controller (ORC) to which it is connected through left or right curtain airbag line 1 and line 2 (or squib) circuits. The hybrid-type inflator assembly for each airbag contains a small canister of highly compressed inert gas. When the ORC sends the proper electrical signal to the airbag inflator, the electrical energy creates enough heat to ignite chemical pellets within the inflator. Once ignited, these chemicals burn rapidly and produce the pressure necessary to rupture a containment disk in the inert gas canister. The inflator and inert gas canister are sealed and connected to a tubular manifold so that all of the released gas is directed into the folded curtain airbag cushion, causing the cushion to inflate. As the airbag cushion inflates it will drop down from the roof rail between the edge of the headliner and the side glass/body pillars to form a curtain-like cushion to protect the vehicle occupants during a side impact collision. The front tethers keep the front portion of the side airbag cushion taut to the side, as does the rear tether for the rear portion of the cushion on mega cab vehicles, thus ensuring that the bag will deploy in the proper position. Following the airbag deployment, the airbag cushion quickly deflates by venting the inert gas through the loose weave of the cushion fabric, and the deflated cushion hangs down loosely from the roof rail. Proper diagnosis of the side curtain airbag inflator and the curtain airbag squib circuits requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Air Bag-Side Curtain > Page 13760 Air Bag: Description and Operation Air Bag-Driver Description DESCRIPTION The color-keyed, injection molded, thermoplastic driver airbag protective trim cover (2) is the most visible part of the driver airbag. The driver airbag is located in the center of the steering wheel (1), where it is secured with two screws to the armature of the four-spoke steering wheel. All vehicles have a chrome Dodge Ram emblem in the center of the trim cover. Concealed beneath the driver airbag trim cover are the horn switch, the folded airbag cushion, the airbag cushion retainer, the airbag housing, the airbag inflator, and the retainers that secure the inflator to the airbag housing. The airbag cushion, housing (5), and inflator (3) are secured within an integral receptacle molded into the back of the trim cover (4). The four vertical walls of this receptacle have a total of 12 small windows with blocking tabs that are engaged by 12 hook formations around the perimeter of the airbag housing. Each hook is inserted through one of the windows and the blocking tab in each window keeps the hook properly engaged with the trim cover, locking the trim cover securely into place on the airbag housing. The resistive membrane-type horn switch is secured with heat stakes to the inside surface of the driver airbag trim cover, between the trim cover and the folded airbag cushion. The horn switch ground pigtail wire has an eyelet terminal connector that is captured beneath a flanged nut on the upper right inflator mounting stud on the back of the housing. The horn switch feed pigtail wire has a black, molded plastic insulator (1) that is secured by an integral retainer in a locator hole near the upper right corner of the airbag housing and is connected to the vehicle electrical system through a dedicated take out and connector of the steering wheel wire harness. Both horn switch wires are routed through an integral notch in the center of the upper edge of the airbag housing stamping. The airbag used in this vehicle is a multistage, Next Generation-type that complies with revised federal airbag standards to deploy with less force than those used in some prior vehicles. A 71 centimeter (28 inch) diameter, radial deploying fabric cushion with internal tethers is used. The airbag inflator is a dual-initiator, non-azide, pyrotechnic-type unit with four mounting studs and is secured to the stamped metal airbag housing by four flanged hex nuts. Two keyed and color-coded connector receptacles on the driver airbag inflator connect the two inflator initiators to the vehicle electrical system through two yellow-jacketed, two-wire pigtail harnesses of the clockspring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Air Bag-Side Curtain > Page 13761 The driver airbag unit cannot be repaired, and must be replaced if deployed, ineffective or in any way damaged. The driver airbag trim cover and horn switch unit may be disassembled from the driver airbag unit, and is available for separate service replacement. Operation OPERATION The multistage driver airbag is deployed by electrical signals generated by the Occupant Restraint Controller (ORC) through the driver airbag squib 1 and squib 2 circuits to the two initiators in the airbag inflator. By using two initiators, the airbag can be deployed at multiple levels of force. The force level is controlled by the ORC to suit the monitored impact conditions by providing one of three delay intervals between the electrical signals provided to the two initiators. The longer the delay between these signals, the less forcefully the airbag will deploy. When the ORC sends the proper electrical signals to each initiator, the electrical energy generates enough heat to initiate a small pyrotechnic charge which, in turn ignites chemical pellets within the inflator. Once ignited, these chemical pellets burn rapidly and produce a large quantity of inert gas. The inflator is sealed to the back of the airbag housing and a diffuser in the inflator directs all of the inert gas into the airbag cushion, causing the cushion to inflate. As the cushion inflates, the driver airbag trim cover will split at predetermined breakout lines, then fold back out of the way along with the horn switch unit. Following an airbag deployment, the airbag cushion quickly deflates by venting the inert gas towards the instrument panel through vent holes within the fabric used to construct the back (steering wheel side) panel of the airbag cushion. Some of the chemicals used to create the inert gas may be considered hazardous while in their solid state before they are burned, but they are securely sealed within the airbag inflator. Typically, both initiators are used and all potentially hazardous chemicals are burned during an airbag deployment event. However, it is possible for only one initiator to be used during a deployment due to an airbag system fault; therefore, it is necessary to always confirm that both initiators have been used in order to avoid the improper disposal of potentially live pyrotechnic or hazardous materials. The inert gas that is produced when the chemicals are burned is harmless. However, a small amount of residue from the burned chemicals may cause some temporary discomfort if it contacts the skin, eyes, or breathing passages. If skin or eye irritation is noted, rinse the affected area with plenty of cool, clean water. If breathing passages are irritated, move to another area where there is plenty of clean, fresh air to breath. If the irritation is not alleviated by these actions, contact a physician. Proper diagnosis of the driver airbag inflator and squib circuits requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Air Bag-Side Curtain > Page 13762 Air Bag: Description and Operation Air Bag-Passenger Description DESCRIPTION The horizontal surface of the injection molded, thermoplastic passenger airbag door (1) is the most visible part of the passenger airbag. The passenger airbag door is located above the glove box opening on the top of the instrument panel (2) in front of the front seat passenger seating position. The forward and outboard edges of the airbag door are secured with integral snap features (3) to the instrument panel base trim, while the rearward edge has several interlocking tabs that engage slots in the base trim. Located below the passenger airbag door (2) within the instrument panel is the passenger airbag unit. The passenger airbag unit is secured by two screws through a stamped mounting bracket (5) to a support bracket welded onto the instrument panel structural support. The passenger airbag housing fits into a molded receptacle on the back of the airbag door, where several stamped hook formations on the forward and rearward edges of the airbag housing are engaged in mating small window openings on the forward and rearward flanges of the receptacle to secure the airbag door to the airbag housing. These airbag door fasteners and mounting provisions are all concealed beneath the instrument panel base trim. The passenger airbag unit used in this vehicle is a multistage, Next Generation-type that complies with revised federal airbag standards to deploy with less force than those used in some prior vehicles. The passenger airbag unit consists of a stamped and welded metal housing, the airbag cushion, the airbag inflator, and a stamped metal airbag cushion retainer plate that is secured to the airbag housing with four studs and nuts. The airbag housing contains the airbag inflator and the folded airbag cushion. An approximately 80 centimeter (31.5 inch) wide by 90 centimeter (35.5 inch) high rectangular fabric cushion is used. The airbag inflator (4) is a non-azide, pyrotechnic-type unit that is secured to and sealed within the airbag housing. A short four-wire pigtail harness with a keyed, yellow connector insulator (1) connects the two inflator initiators to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Air Bag-Side Curtain > Page 13763 The passenger airbag includes the airbag door. This unit cannot be repaired, and must be replaced if deployed, ineffective, or in any way damaged. Operation OPERATION The multistage passenger airbag is deployed by electrical signals generated by the Occupant Restraint Controller (ORC) through the passenger airbag squib 1 and squib 2 circuits to the two initiators in the airbag inflator. By using two initiators, the airbag can be deployed at multiple levels of force. The force level is controlled by the ORC to suit the monitored impact conditions by providing one of three delay intervals between the electrical signals provided to the two initiators. The longer the delay between these signals, the less forcefully the airbag will deploy. When the ORC sends the proper electrical signals to each initiator, the electrical energy generates enough heat to initiate a small pyrotechnic charge which, in turn ignites chemical pellets within the inflator. Once ignited, these chemical pellets burn rapidly and produce a large quantity of inert gas. The inflator is sealed to the airbag cushion and a diffuser in the inflator directs all of the inert gas into the airbag cushion, causing the cushion to inflate. As the cushion inflates, the passenger airbag door will split at predetermined tear seam lines concealed on the inside surface of the door, then the door will pivot up over the top of the instrument panel and out of the way. Following an airbag deployment, the airbag cushion quickly deflates by venting the inert gas through a vent hole in each fabric side panel of the airbag cushion. Typically, both initiators are used during an airbag deployment event. However, it is possible for only one initiator to be used during a deployment due to an airbag system fault; therefore, it is necessary to always confirm that both initiators have been used in order to avoid the improper disposal of potentially live pyrotechnic materials. Proper diagnosis of the passenger airbag inflator and the passenger airbag squib circuits requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement Air Bag: Removal and Replacement Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury when removing a deployed airbag, rubber gloves, eye protection, and a long-sleeved shirt should be worn. There may be deposits on the airbag unit and other interior surfaces. In large doses, these deposits may cause irritation to the skin and eyes. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the side curtain airbag, or becoming entrapped between the side curtain airbag cushion and the headliner. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedure is for replacement of an ineffective or damaged side curtain airbag. If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints.. If the side curtain airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the headliner from the vehicle. 3. On mega cab vehicles only, remove the screw and disengage the two retainers that secure the side curtain airbag rear tether to the inner C-pillar near the cab back panel. 4. Remove the screw (6) that secures the side curtain airbag front tether retainer (5) to the base of the A-pillar near the belt line. 5. Disengage the two side curtain airbag front tether plastic retainer clips (4) from the A-pillar. 6. Disconnect the body wire harness connector (9) for the side curtain airbag from the connector receptacle at the back of the inflator. 7. Working from front to rear, remove the four (standard cab), five (quad cab) or eight (mega cab) screws (3) that secure the side curtain airbag inflator and manifold tube brackets to the spring nuts (2) in the roof rail (1). 8. Disengage the three (standard cab), four (quad cab) or six (mega cab) plastic push-in fasteners (8) that secure the side curtain airbag to the roof rail. 9. Remove the side curtain airbag (7) from the vehicle as a unit. Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 13766 any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury when removing a deployed airbag, rubber gloves, eye protection, and a long-sleeved shirt should be worn. There may be deposits on the airbag unit and other interior surfaces. In large doses, these deposits may cause irritation to the skin and eyes. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the side curtain airbag, or becoming entrapped between the side curtain airbag cushion and the headliner. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedure is for replacement of an ineffective or damaged side curtain airbag. If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the side curtain airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. 1. Check to be certain that the four (standard cab), six (quad cab) or eight (mega cab) spring nuts (2) are properly installed in the inner roof rail (1) and that they are in good condition. 2. Position the side curtain airbag (7) into the vehicle as a unit. 3. Working from rear to front, align each of the three (standard cab), four (quad cab) or six (mega cab) plastic push-in fasteners (8) on the side curtain airbag with their holes in the inner roof side rail and push them straight in until they are fully seated. 4. Working from rear to front, install and tighten the four (standard cab), five (quad cab) or eight (mega cab) screws (3) that secure the side curtain airbag to the spring nuts in the inner roof rail. Tighten the screws to 6 Nm (50 in. lbs.). 5. Reconnect the body wire harness connector (9) for the side curtain airbag to the connector receptacle at the back of the inflator. Be certain that the connector is fully engaged and latched. 6. Engage the two plastic retainer clips (4) that secure the side curtain airbag front tether to the inner A-pillar. 7. Install and tighten the screw (6) that secures the front tether retainer (5) to the base of the A-pillar near the belt line. Tighten the screw to 6 Nm (55 in. lbs.). 8. On mega cab vehicles only, engage the two retainer clips that secure the side curtain airbag rear tether to the inner C-pillar near the cab back panel. 9. On mega cab vehicles only, install and tighten the screw that secures the rear tether retainer to the inner C-pillar near the cab back panel. Tighten the screw to 6 Nm (55 in. lbs.). 10. Reinstall the headliner into the vehicle. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 13767 any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury when removing a deployed airbag, rubber gloves, eye protection, and a long-sleeved shirt should be worn. There may be deposits on the airbag cushion and other interior surfaces. In large doses, these deposits may cause irritation to the skin and eyes. NOTE: The following procedure is for replacement of an ineffective or damaged driver airbag. If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the driver airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. From the underside of the steering wheel, remove the two screws (3) that secure the driver airbag (1) to the steering wheel armature (2). CAUTION: Do not pull on the horn switch feed pigtail wire to disengage the connector from the driver airbag housing or to disconnect the horn switch to steering wheel wire harness connection. Improper pulling on this pigtail wire or connection can result in damage to the horn switch membrane or feed circuit. 3. Pull the driver airbag (1) away from the steering wheel far enough to access the three electrical connections on the back of the airbag housing. 4. Disconnect the steering wheel wire harness connector for the horn switch (2) from the horn switch feed pigtail wire connector (4), which is located on the back of the driver airbag housing. CAUTION: Do not pull on the clockspring pigtail wires or pry on the connector insulator to disengage the connector from the driver airbag inflator connector receptacle. Improper removal of these pigtail wires and their connector insulators can result in damage to the airbag circuits or connector insulators. 5. The clockspring driver airbag pigtail wire connectors (3) are secured by integral latches to the airbag inflator connector receptacles, which are located on the back of the driver airbag housing. Depress the latches on each side of the connector insulator and pull the insulators straight out Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 13768 from the airbag inflator to disconnect them from the connector receptacles. 6. Remove the driver airbag from the steering wheel. 7. If the driver airbag has been deployed, the clockspring must be replaced. Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the driver airbag, or becoming entrapped between the driver airbag cushion and the driver airbag trim cover. Failure to observe this warning could result in occupant injuries upon airbag deployment. WARNING: To avoid serious or fatal injury, the driver airbag trim cover must never be painted. Replacement airbags are serviced with trim covers in the original colors. Paint may change the way in which the material of the trim cover responds to an airbag deployment. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedure is for replacement of an ineffective or damaged driver airbag. If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the driver airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. 1. Position the driver airbag (1) close enough to the steering wheel to reconnect the three electrical connections on the back of the airbag housing. 2. When installing the driver airbag, reconnect the two clockspring driver airbag pigtail wire connectors (3) to the airbag inflator connector receptacles by pressing straight in on the connector. Be certain to engage each keyed and color-coded connector to the matching connector receptacle. You can be certain that each connector is fully engaged in its receptacle by listening carefully for a distinct, audible click as the connector latches snap into place. 3. Reconnect the steering wheel wire harness connector (2) for the horn switch to the horn switch feed pigtail wire connector (4), which is located on the back of the driver airbag housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 13769 4. Carefully position the driver airbag (1) in the steering wheel (2). Be certain that the clockspring pigtail wires and the steering wheel wire harness in the steering wheel hub area are not pinched between the driver airbag and the steering wheel armature. 5. From the underside of the steering wheel, install and tighten the two screws (3) that secure the driver airbag to the steering wheel armature. Tighten the screws to 10 Nm (90 in. lbs.). WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury when removing a deployed airbag, rubber gloves, eye protection, and a long-sleeved shirt should be worn. There may be deposits on the airbag unit and other interior surfaces. In large doses, these deposits may cause irritation to the skin and eyes. NOTE: The following procedure is for replacement of an ineffective or damaged passenger airbag. If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the passenger airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the top cover from the top of the instrument panel. 3. Remove the glove box from the instrument panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 13770 4. Reach up into the instrument panel between the upper glove box opening reinforcement and the cross car beam (4) to access and disconnect the instrument panel wire harness connector (2) from the airbag inflator pigtail wire connector on the right side of the instrument panel airbag support bracket. To disconnect the connector: a. Slide the red Connector Position Assurance (CPA) lock on the top of the connector toward the side of the connector. b. Depress the connector latch tab and pull the two halves of the connector straight away from each other. 5. Remove the two screws (3) that secure the passenger airbag lower bracket to the instrument panel airbag support bracket. 6. Disengage the airbag inflator pigtail wire connector (1) from the plastic push-in retainer plate (3) on the right side of the instrument panel airbag support bracket. To disengage the connector: a. Using a small screwdriver (4), carefully pry the leading edge of the push-in retainer plate away from the connector insulator far enough to clear the engagement tab (2) on the insulator. b. Pull the connector toward you to slide it off of the push-in retainer plate. 7. Using a trim stick (2) or another suitable wide flat-bladed tool, gently pry the forward, then the outboard edges of the passenger airbag door (1) away from the instrument panel (3) far enough to disengage the snap features on the door from the receptacles in the instrument panel base trim. 8. Remove the passenger airbag and airbag door from the instrument panel as a unit. Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the passenger airbag, or becoming entrapped between the passenger airbag cushion and the passenger airbag door. Failure to observe this warning could result in occupant injuries upon airbag deployment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 13771 WARNING: To avoid serious or fatal injury, the passenger airbag door must never be painted. Replacement passenger airbag units are serviced with doors in the original colors. Paint may change the way in which the material of the airbag door responds to an airbag deployment. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedure is for replacement of an ineffective or damaged passenger airbag. If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the passenger airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. 1. Carefully position the passenger airbag and airbag door through the opening in the top of the instrument panel base trim as a unit. Be certain that the rear edge of the passenger airbag lower bracket is engaged in the hook formation (5) of the instrument panel airbag support bracket, and the anti-rotation tabs (1) on either side of the hook are engaged in the two holes in the airbag lower bracket. 2. Install and tighten the two screws (3) that secure the passenger airbag lower bracket to the instrument panel airbag support bracket. Tighten the screws to 6 Nm (55 in. lbs.). 3. Slide the airbag inflator pigtail wire connector onto the plastic push-in retainer plate on the right side of the instrument panel airbag support bracket far enough snap it into place over the engagement tab on the connector insulator. 4. Reconnect the instrument panel wire harness connector to the passenger airbag pigtail wire connector on the right side of the airbag lower mounting bracket. Be certain that the latch on the connector and the red Connector Position Assurance (CPA) lock are each fully engaged. 5. Engage the interlocking tabs on the rear edge of the passenger airbag door into the corresponding slots in the instrument panel base trim. 6. Using hand pressure, push down on the passenger airbag door over each snap feature on both sides and the forward edge of the airbag door until it snaps into its receptacle in the instrument panel base trim. 7. Reinstall the glove box into the instrument panel. 8. Reinstall the top cover onto the top of the instrument panel. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 13772 Air Bag: Overhaul Disassembly DISASSEMBLY WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, service of this unit should be performed only by DaimlerChrysler-trained and authorized dealer service technicians. Failure to take the proper precautions or to follow the proper procedures could result in accidental, incomplete, or improper airbag deployment and possible occupant injuries. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the driver airbag, or becoming entrapped between the driver airbag cushion and the driver airbag trim cover. Failure to observe this warning could result in occupant injuries upon airbag deployment. WARNING: To avoid serious or fatal injury, the driver airbag trim cover must never be painted. Replacement trim covers are serviced in the original colors. Paint may change the way in which the material of the trim cover responds to an airbag deployment. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedures can be used to replace the driver airbag trim cover and horn switch unit for service. If the driver airbag is ineffective or deployed, the entire driver airbag, trim cover and horn switch must be replaced as a unit. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the driver airbag from the steering wheel. 3. Place the driver airbag on a suitable clean and dry work surface with the trim cover facing down. If the trim cover will be reused, be certain to take the proper precautions to prevent the trim cover from receiving cosmetic damage during the following procedures. 4. Carefully pry the horn switch feed pigtail wire connector (1) away from the back of the driver airbag housing (3) far enough to disengage the integral connector retainer from the locator hole just above the upper right inflator mounting stud. 5. Remove the nut that secures the horn switch ground pigtail wire eyelet terminal (2) to the upper right inflator stud on the back of the driver airbag housing. 6. Remove the horn switch ground pigtail wire eyelet terminal from the upper right inflator stud on the back of the driver airbag housing. 7. Disengage each of the 12 hooks (5 and 6) of the airbag housing from the 12 windows in the vertical walls of the trim cover (4), one wall at a time. Start by disengaging the upper wall, then do each of the two side walls, and finish with the lower wall. To disengage the hooks, use hand pressure to push the adjacent edge of the airbag housing firmly and evenly downward into the trim cover receptacle, while at the same time pushing outward on the upper edge of the receptacle wall. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 13773 8. With all of the hooks disengaged, lift the housing, inflator, and cushion as a unit from the receptacle on the back of the driver airbag trim cover. Assembly ASSEMBLY WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, service of this unit should be performed only by DaimlerChrysler-trained and authorized dealer service technicians. Failure to take the proper precautions or to follow the proper procedures could result in accidental, incomplete, or improper airbag deployment and possible occupant injuries. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the driver airbag, or becoming entrapped between the driver airbag cushion and the driver airbag trim cover. Failure to observe this warning could result in occupant injuries upon airbag deployment. WARNING: To avoid serious or fatal injury, the driver airbag trim cover must never be painted. Replacement trim covers are serviced in the original colors. Paint may change the way in which the material of the trim cover responds to an airbag deployment. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedures can be used to replace the driver airbag trim cover and horn switch unit for service. If the driver airbag is ineffective or deployed, the entire driver airbag, trim cover and horn switch must be replaced as a unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 13774 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Component ID: 208 Component : MODULE-OCCUPANT RESTRAINT CONTROLLER Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C1 Color : YELLOW # of pins : 24 Pin Description Circuit 1-2-3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT 5-6 PASSENGER AIRBAG INDICATOR DRIVER G104 20VT/GY 7 PASSENGER AIRBAG MUX SWITCH RETURN R104 20LB/LG 8 PASSENGER AIRBAG MUX SWITCH SENSE R106 20LG/LB 9 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 10 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT 11 RIGHT FRONT IMPACT SENSOR GROUND R82 20WT/LB 12 RIGHT FRONT IMPACT SENSOR SIGNAL R80 20VT/LB 13 - 14 - 15 - 16 - 17 DRIVER SQUIB 1 LINE 1 R43 20LG/BR 18 DRIVER SQUIB 1 LINE 2 R45 20LG/OR 19 PASSENGER SQUIB 1 LINE 2 R44 20LB/OR 20 PASSENGER SQUIB 1 LINE 1 R42 20LB/BR 21 DRIVER SQUIB 2 LINE 1 R61 20LG/VT 22 DRIVER SQUIB 2 LINE 2 R63 20LG/WT 23 PASSENGER SQUIB 2 LINE 1 R64 20LB/WT 24 PASSENGER SQUIB 2 LINE 2 R62 20LB/VT Component Location - 58 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 13778 Component Location - 63 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 13779 Component Location - 51 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 13780 Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C2 Color : YELLOW # of pins : 32 Pin Description Circuit 1 RIGHT CURTAIN SQUIB 1 LINE 2 R2 20WT/LB 2 RIGHT CURTAIN SQUIB 1 LINE 1 R4 20OR/LB 3 LEFT CURTAIN SQUIB 1 LINE 1 R3 20LB/OR 4 LEFT CURTAIN SQUIB 1 LINE 2 R1 20LB/WT 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 13781 6-7-8-9 DRIVER SEAT BELT TENSIONER LINE 2 R53 20LG/YL 10 DRIVER SEAT BELT TENSIONER LINE 1 R55 20LG/DG 11 PASSENGER SEAT BELT TENSIONER LINE 1R56 20LB/DG 12 PASSENGER SEAT BELT TENSIONER LINE 2R54 20LB/YL 13 LEFT CURTAIN SQUIB 1 LINE 2 R1 20LB/WT 14 LEFT CURTAIN SQUIB 1 LINE 1 R3 20LB/OR 15 RIGHT CURTAIN SQUIB 1 LINE 1 R4 20OR/LB 16 RIGHT CURTAIN SQUIB 1 LINE 2 R2 20WT/LB 17 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 18 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20PK/VT 19 - 20 GROUND Z104 18BK/LG 21 - 22 - 23 - 24 - 25 DRIVER SEAT POSITION SENSOR DATA R261 20LB/TN 26 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/GY 27 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 28 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 29 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 30 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 31 - 32 - Component Location - 58 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 13782 Component Location - 63 Component Location - 51 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 13783 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 13784 Air Bag Control Module: Diagrams Component ID: 208 Component : MODULE-OCCUPANT RESTRAINT CONTROLLER Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C1 Color : YELLOW # of pins : 24 Pin Description Circuit 1-2-3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT 5-6 PASSENGER AIRBAG INDICATOR DRIVER G104 20VT/GY 7 PASSENGER AIRBAG MUX SWITCH RETURN R104 20LB/LG 8 PASSENGER AIRBAG MUX SWITCH SENSE R106 20LG/LB 9 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 10 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT 11 RIGHT FRONT IMPACT SENSOR GROUND R82 20WT/LB 12 RIGHT FRONT IMPACT SENSOR SIGNAL R80 20VT/LB 13 - 14 - 15 - 16 - 17 DRIVER SQUIB 1 LINE 1 R43 20LG/BR 18 DRIVER SQUIB 1 LINE 2 R45 20LG/OR 19 PASSENGER SQUIB 1 LINE 2 R44 20LB/OR 20 PASSENGER SQUIB 1 LINE 1 R42 20LB/BR 21 DRIVER SQUIB 2 LINE 1 R61 20LG/VT 22 DRIVER SQUIB 2 LINE 2 R63 20LG/WT 23 PASSENGER SQUIB 2 LINE 1 R64 20LB/WT 24 PASSENGER SQUIB 2 LINE 2 R62 20LB/VT Component Location - 58 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 13785 Component Location - 63 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 13786 Component Location - 51 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 13787 Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C2 Color : YELLOW # of pins : 32 Pin Description Circuit 1 RIGHT CURTAIN SQUIB 1 LINE 2 R2 20WT/LB 2 RIGHT CURTAIN SQUIB 1 LINE 1 R4 20OR/LB 3 LEFT CURTAIN SQUIB 1 LINE 1 R3 20LB/OR 4 LEFT CURTAIN SQUIB 1 LINE 2 R1 20LB/WT 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 13788 6-7-8-9 DRIVER SEAT BELT TENSIONER LINE 2 R53 20LG/YL 10 DRIVER SEAT BELT TENSIONER LINE 1 R55 20LG/DG 11 PASSENGER SEAT BELT TENSIONER LINE 1R56 20LB/DG 12 PASSENGER SEAT BELT TENSIONER LINE 2R54 20LB/YL 13 LEFT CURTAIN SQUIB 1 LINE 2 R1 20LB/WT 14 LEFT CURTAIN SQUIB 1 LINE 1 R3 20LB/OR 15 RIGHT CURTAIN SQUIB 1 LINE 1 R4 20OR/LB 16 RIGHT CURTAIN SQUIB 1 LINE 2 R2 20WT/LB 17 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 18 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20PK/VT 19 - 20 GROUND Z104 18BK/LG 21 - 22 - 23 - 24 - 25 DRIVER SEAT POSITION SENSOR DATA R261 20LB/TN 26 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/GY 27 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 28 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 29 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 30 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 31 - 32 - Component Location - 58 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 13789 Component Location - 63 Component Location - 51 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 13790 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Description and Operation > Description Air Bag Control Module: Description and Operation Description DESCRIPTION The Occupant Restraint Controller (ORC) (1) is located in the passenger compartment of the vehicle, where it is secured by three nuts to three studs on a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel under the center front seat or the center floor console, as the vehicle is equipped. Concealed within a hollow in the center of the die cast aluminum ORC housing is the electronic circuitry of the ORC which includes a microprocessor, an electronic impact sensor, an electronic safing sensor, and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ORC housing with screws to enclose and protect the internal electronic circuitry and components. An arrow (2) printed on the label (3) on the top of the ORC housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ORC housing has integral mounting flanges on three corners. The mounting flange to the right of the connector receptacles (4) has an integral locating pin on its lower surface. Both right side flanges have round mounting holes, while the flange on the left side has a slotted mounting hole. A molded plastic electrical connector (4) with 2 receptacles, one containing 24 terminal pins and the other containing 32 terminal pins, exits the forward facing side of the ORC housing. These terminal pins connect the ORC to the vehicle electrical system through two dedicated take outs and connectors, one each from the instrument panel and the body wire harnesses. A molded plastic protective cover is installed over the ORC to provide additional moisture contamination protection to the unit. Integral latch features on each side of the cover engage a slot (5) on each side of the base of the ORC housing to secure the cover to the ORC. This protective cover must be reinstalled following any service requiring its removal. The impact sensor and safing sensor internal to the ORC are calibrated for the specific vehicle, and are only serviced as a unit with the ORC. In addition, there are unique versions of the ORC for light and heavy-duty vehicles, and for vehicles with or without the optional side curtain airbags. The ORC cannot be repaired or adjusted and, if damaged or ineffective, it must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Description and Operation > Description > Page 13793 Air Bag Control Module: Description and Operation Operation OPERATION The microprocessor in the Occupant Restraint Controller (ORC) contains the supplemental restraint system logic circuits and controls all of the supplemental restraint system components. The ORC uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Controller Area Network (CAN) data bus. This method of communication is used for control of the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) and for supplemental restraint system diagnosis and testing through the 16-way Data Link Connector (DLC) located on the driver side lower edge of the instrument panel. The ORC microprocessor continuously monitors all of the supplemental restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC over the CAN data bus to turn ON the airbag indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the ORC. For some DTCs, if a fault does not recur for a number of ignition cycles, the ORC will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. In standard cab vehicles, the ORC also monitors a resistor multiplexed input from the passenger airbag on/off switch. If the passenger airbag on/off switch is set to the OFF position, the ORC turns ON the passenger airbag on/off indicator and will internally disable the passenger airbag and seat belt tensioner from being deployed. The ORC receives battery current through two circuits; a fused ignition switch output (run) circuit through a fuse in the Totally Integrated Power Module (TIPM), and a fused ignition switch output (run-start) circuit through a second fuse in the TIPM. The ORC receives ground through a ground circuit and take out of the instrument panel wire harness. This take out has a single eyelet terminal connector that is secured by a ground screw to the instrument panel structural support. These connections allow the ORC to be operational whenever the ignition switch is in the START or ON positions. The ORC also contains an energy-storage capacitor. When the ignition switch is in the START or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the supplemental restraint components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup supplemental restraint system protection in case there is a loss of battery current supply to the ORC during an impact. Two sensors are contained within the ORC, an electronic impact sensor and a safing sensor. The ORC also monitors inputs from two remote front impact sensors located on the back of the right and left ends of the lower radiator crossmember near the front of the vehicle. The electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provide verification of the direction and severity of an impact. On vehicles equipped with optional side curtain airbags the ORC also monitors inputs from two additional remote impact sensors located within both the left and right B-pillars to control deployment of the side curtain airbag units. The safing sensor is an electronic accelerometer sensor within the ORC that provides an additional logic input to the ORC microprocessor. The safing sensor is used to verify the need for a supplemental restraint deployment by detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags to deploy. Vehicles equipped with optional side curtain airbags feature a second safing sensor within the ORC to provide confirmation to the ORC microprocessor of side impact forces. This second safing sensor is a bi-directional unit that detects impact forces from either side of the vehicle. Pre-programmed decision algorithms in the ORC microprocessor determine when the deceleration rate as signaled by the impact sensors and the safing sensors indicate an impact that is severe enough to require supplemental restraint system protection and, based upon the severity of the monitored impact, determines the level of front airbag deployment force required for each front seating position. When the programmed conditions are met, the ORC sends the proper electrical signals to deploy the dual multistage front airbags at the programmed force levels, the front seat belt tensioners and, if the vehicle is so equipped, either side curtain airbag unit. On standard cab vehicles, the passenger front airbag and seat belt tensioner will be deployed by the ORC only if enabled by the passenger airbag on/off switch at the time of the impact. The hard wired inputs and outputs for the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ORC or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the ORC or the electronic controls and communication related to ORC operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal Air Bag Control Module: Service and Repair Removal Module MODULE WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the occupant restraint controller, as it can damage the impact sensor or affect its calibration. The occupant restraint controller contains the impact sensor, which enables the system to deploy the supplemental restraints. If an occupant restraint controller is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the protective cover from the Occupant Restraint Controller (ORC) (1). 3. Unlatch and disconnect the two wire harness connectors (3) for the ORC from the ORC connector receptacles (2 and 4) located on the forward facing side of the module. To disconnect the wire harness connectors from the ORC, depress the release tab and lift the lever arm on each connector. 4. Remove the three nuts (2) that secure the ORC (1) to the studs on the ORC mounting bracket (3) on the floor panel transmission tunnel. 5. Remove the ORC from the floor panel transmission tunnel. Cover Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal > Page 13796 COVER WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. NOTE: The front seat assembly must be unfastened from the floor panel, but need not be removed from the vehicle for access to the Occupant Restraint Controller (ORC) cover for service. 2. Remove the front seat from the vehicle. 3. Using a trim stick or another suitable wide flat-bladed tool, gently pry the latch feature on either side of the ORC cover (1) away from the base of the ORC (2) far enough to disengage the cover from the module. 4. Remove the ORC cover from over the ORC. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal > Page 13797 Air Bag Control Module: Service and Repair Installation Module MODULE WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the occupant restraint controller, as it can damage the impact sensor or affect its calibration. The occupant restraint controller contains the impact sensor, which enables the system to deploy the supplemental restraints. If an occupant restraint controller is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. 1. Position the Occupant Restraint Controller (ORC) (1) over the three studs of the ORC mounting bracket (3) on the floor panel transmission tunnel, then engage the locating pin on the bottom of the right ORC mounting flange into the locating hole in the bracket. When the ORC is correctly positioned, the arrow on the ORC label will be pointed forward in the vehicle. 2. Install and tighten the three nuts (2) that secure the ORC to the bracket on the floor panel transmission tunnel. Tighten the nuts to 10 Nm (7 ft. lbs.). 3. Reconnect the two wire harness connectors (3) for the ORC (1) to the ORC connector receptacles (2 and 4) located on the forward facing side of the module. Be certain that the latches on the connectors are each fully engaged. 4. Reinstall the ORC cover onto the ORC. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal > Page 13798 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Cover COVER WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the ORC cover (1) over the Occupant Restraint Controller (ORC) (2). 2. Align the latch feature on each side of the ORC cover with the notch in each side at the base of the ORC housing. 3. Using hand pressure, press firmly and evenly downward on the ORC cover until each latch feature is fully engaged with the ORC housing. 4. Reinstall the front seat into the vehicle. 5. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations Air Bag Deactivation Switch: Locations Component ID: 475 Component : SWITCH-PASSENGER AIRBAG ON/OFF Connector: Name : SWITCH-PASSENGER AIRBAG ON/OFF Color : BLACK # of pins : 6 Pin Description Circuit 1 PASSENGER AIRBAG MUX SWITCH SENSE R106 20LG/LB 2 PASSENGER AIRBAG MUX SWITCH RETURN R104 20LB/LG 3 PASSENGER AIRBAG INDICATOR DRIVER G104 20VT/GY 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 5-6-Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 13802 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 13803 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 13804 Air Bag Deactivation Switch: Diagrams Component ID: 475 Component : SWITCH-PASSENGER AIRBAG ON/OFF Connector: Name : SWITCH-PASSENGER AIRBAG ON/OFF Color : BLACK # of pins : 6 Pin Description Circuit 1 PASSENGER AIRBAG MUX SWITCH SENSE R106 20LG/LB 2 PASSENGER AIRBAG MUX SWITCH RETURN R104 20LB/LG 3 PASSENGER AIRBAG INDICATOR DRIVER G104 20VT/GY 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 5-6-Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 13805 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 13806 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Description Air Bag Deactivation Switch: Description and Operation Description DESCRIPTION The passenger airbag on/off switch (1) is standard equipment on all standard cab versions of this vehicle equipped with the dual front airbag system. This switch is a two-position, resistor multiplexed switch with a single integral amber Light-Emitting Diode (LED), and a non-coded key cylinder-type actuator. The switch is located in the lower right corner of the instrument panel center bezel, near the center of the instrument panel. When the switch is in its installed position, the only components visible through the dedicated opening of the center bezel are the switch bezel (2) and lens, the nomenclature imprinted on the lens, and the key cylinder actuator (3). The OFF position nomenclature of the switch is illuminated and visible only when that switch position is selected. The ON position of the switch is neither visible or illuminated but can be determined by the orientation of the slot of the key cylinder actuator. The remainder of the switch is concealed behind the switch bezel and the instrument panel center bezel. The passenger airbag on/off switch housing is constructed of molded plastic and has three integral mounting tabs. These mounting tabs are used to secure the switch to the back of the molded plastic switch bezel with three small screws. The molded plastic switch bezel also has three integral mounting tabs that are used to secure the switch and bezel unit to the instrument panel center bezel with three additional screws. A molded plastic connector receptacle on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The molded plastic harness connector insulator is keyed and latched to ensure proper and secure switch electrical connections. The passenger airbag on/off switch cannot be adjusted or repaired and, if ineffective or damaged, the switch must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Description > Page 13809 Air Bag Deactivation Switch: Description and Operation Operation OPERATION The passenger airbag on/off switch allows the customer to turn the passenger airbag function ON or OFF to accommodate certain uses of the right front seating position where airbag protection may not be desired. See the owner's manual in the vehicle glove box for specific recommendations on when to enable or disable the passenger airbag. The OFF indicator of the switch will be illuminated whenever the switch is turned to the OFF position and the ignition switch is in the ON position. The ignition key is the only key or object that should ever be inserted into the key cylinder actuator of the switch. The on/off switch requires only a partial key insertion to fully depress a spring-loaded locking plunger. The spring-loaded locking plunger prevents the user from leaving the key in the switch. The key will be automatically ejected when force is not applied. To actuate the passenger airbag on/off switch, insert the ignition key into the switch key actuator far enough to fully depress the plunger, then rotate the actuator to the desired switch position. When the switch key actuator is rotated to its clockwise stop (the key actuator slot will be aligned with the OFF nomenclature), the OFF indicator is illuminated and the passenger airbag is disabled. When the switch is rotated to its counterclockwise stop (the key actuator slot will be in a vertical position) the OFF indicator will be extinguished and the passenger airbag is enabled. The OFF indicator and the enabling or disabling of the passenger airbag is controlled electronically by the Occupant Restraint Controller (ORC) based upon inputs it receives from the on/off switch. The passenger airbag on/off switch connects one of two internal resistors in series between the passenger airbag MUX switch sense and passenger airbag mux switch return circuits of the ORC. The ORC continually monitors the resistance in these circuits to determine the switch position that has been selected. When the switch is in the OFF position, the ORC provides a ground input to the OFF indicator through the passenger airbag indicator driver circuit, which energizes the Light-Emitting Diode (LED) that illuminates the indicator. The ORC will store a Diagnostic Trouble Code (DTC) for any fault it detects in the passenger airbag on/off switch or OFF indicator circuits, and will illuminate the airbag indicator in the instrument cluster if a fault is detected. The hard wired circuits between the passenger airbag on/off switch and the ORC may be diagnosed using conventional diagnostic tools and procedures. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the passenger airbag on/off switch or the electronic controls and communication between other modules and devices that provide some features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the passenger airbag on/off switch or the electronic controls and communication related to passenger airbag on/off switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Service and Repair > Removal Air Bag Deactivation Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: A passenger airbag on/off switch is used only on standard cab vehicles equipped with dual front airbags. Quad cab and mega cab vehicles have a cubby bin installed in the instrument panel center bezel in place of the on/off switch. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the center bezel (1) from the instrument panel. 3. From the back of the center bezel, remove the three screws (2) that secure the passenger airbag on/off switch and bezel unit (3) to the back of the center bezel. 4. Remove the passenger airbag on/off switch and bezel from the center bezel as a unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Service and Repair > Removal > Page 13812 Air Bag Deactivation Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: A passenger airbag on/off switch is used only on standard cab vehicles equipped with dual front airbags. Quad cab and mega cab vehicles have a cubby bin installed in the instrument panel center bezel in place of the on/off switch. 1. Position the passenger airbag on/off switch and bezel unit (3) to the back of the center bezel (1). 2. Install and tighten the three screws (2) that secure the passenger airbag on/off switch bezel to the back of the center bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Reinstall the center bezel onto the instrument panel. 4. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Customer Interest for Clockspring Assembly / Spiral Cable: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set Clockspring Assembly / Spiral Cable: Customer Interest ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set NUMBER: 08-044-06 GROUP: Electrical DATE: October 07, 2006 SUBJECT: DTC C1240 - Steering Angle Sensor Over Travel Performance OVERVIEW: This bulletin involves the diagnosis and possible replacement of the Steering Angle Sensor. MODELS: 2007 (DR) Ram Truck NOTE: This bulletin applies to vehicle equipped with the Electronic Stability Program (sales code BNB) and built prior to October 03, 2006 (MDH 1003XX). SYMPTOM/CONDITION: The customer may experience an illumination on the instrument cluster of the "ABS" (Anti-Lock Brake System) and/or the "ESP / BAS" (Electronic Stability Program / Brake Assist System) Warning Lights. Investigation may reveal the presence of Diagnostic Trouble Code (DTC) C1240 Steering Angle Sensor Over Travel Performance (SAS). DIAGNOSIS: 1. Perform the diagnostic test procedure for DTC C1240. This diagnostic procedure can be found on TechCONNECT: select the SERVICE INFO tab > 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 340/445E5P AWAL > DIAGNOSIS and TESTING > C1240 - Steering Angle Sensor Over Travel Performance (SAS). 2. If the diagnostic test procedure for DTC C1240 determines that the Steering Angle Sensor is at fault, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Before starting this procedure, be certain that the front wheels are in the straight-ahead position. 1. Replace the steering column clockspring. Refer to TechCONNECT for detailed service procedures: select the SERVICE INFO tab > 8 - ELECTRICAL > RESTRAINTS > CLOCKSPRING > REMOVAL and INSTALLATION. 2. Clear offsets by initializing the ABS ECU using StarSCAN. 3. Perform the ABS VERIFICATION TEST. This test can be found in: 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 3401445E5P AWAL > STANDARD PROCEDURE > ABS VERIFICATION TEST. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Customer Interest for Clockspring Assembly / Spiral Cable: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set > Page 13821 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set Clockspring Assembly / Spiral Cable: All Technical Service Bulletins ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set NUMBER: 08-044-06 GROUP: Electrical DATE: October 07, 2006 SUBJECT: DTC C1240 - Steering Angle Sensor Over Travel Performance OVERVIEW: This bulletin involves the diagnosis and possible replacement of the Steering Angle Sensor. MODELS: 2007 (DR) Ram Truck NOTE: This bulletin applies to vehicle equipped with the Electronic Stability Program (sales code BNB) and built prior to October 03, 2006 (MDH 1003XX). SYMPTOM/CONDITION: The customer may experience an illumination on the instrument cluster of the "ABS" (Anti-Lock Brake System) and/or the "ESP / BAS" (Electronic Stability Program / Brake Assist System) Warning Lights. Investigation may reveal the presence of Diagnostic Trouble Code (DTC) C1240 Steering Angle Sensor Over Travel Performance (SAS). DIAGNOSIS: 1. Perform the diagnostic test procedure for DTC C1240. This diagnostic procedure can be found on TechCONNECT: select the SERVICE INFO tab > 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 340/445E5P AWAL > DIAGNOSIS and TESTING > C1240 - Steering Angle Sensor Over Travel Performance (SAS). 2. If the diagnostic test procedure for DTC C1240 determines that the Steering Angle Sensor is at fault, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Before starting this procedure, be certain that the front wheels are in the straight-ahead position. 1. Replace the steering column clockspring. Refer to TechCONNECT for detailed service procedures: select the SERVICE INFO tab > 8 - ELECTRICAL > RESTRAINTS > CLOCKSPRING > REMOVAL and INSTALLATION. 2. Clear offsets by initializing the ABS ECU using StarSCAN. 3. Perform the ABS VERIFICATION TEST. This test can be found in: 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 3401445E5P AWAL > STANDARD PROCEDURE > ABS VERIFICATION TEST. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set > Page 13827 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 13828 Clockspring Assembly / Spiral Cable: Locations Component ID: 212 Component : MODULE-STEERING CONTROL Connector: Name : MODULE-STEERING CONTROL C1 Color : WHITE # of pins : 6 Pin Description Circuit 1 GROUND Z909 20BK 2 RADIO CONTROL MUX X20 20GY/WT 3 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 4 S/C SWITCH NO. 1 SIGNAL V37 20VT 5 S/C SWITCH RETURN V937 20VT/BR 6 HORN SWITCH SENSE X3 20DG/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 13829 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 13830 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 13831 Connector: Name : MODULE-STEERING CONTROL C2 Color : BLACK # of pins : 2 Qualifier : (PREMIUM) Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 13832 2 RADIO CONTROL MUX X20 22GY/WT 2 RADIO CONTROL MUX X20 22GY/WT Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 13833 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 13834 Connector: Name : MODULE-STEERING CONTROL C3 Color : # of pins : 4 Pin Description Circuit 1 HORN SWITCH SENSE X3 20DG/VT 2 S/C SWITCH RETURN V937 22DB/DG 2 SENSOR GROUND K900 22DB/DG 3 S/C SWITCH NO. 1 SIGNAL V37 22VT 4 S/C SWITCH NO. 2 SIGNAL V38 22VT/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 13835 Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 13836 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 13837 Connector: Name : MODULE-STEERING CONTROL C4 Color : YELLOW # of pins : 4 Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R61 20LG/VT 2 DRIVER SQUIB 2 LINE 2 R63 20LG/WT 3 DRIVER SQUIB 1 LINE 1 R43 20LG/BR 4 DRIVER SQUIB 1 LINE 2 R45 20LG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 13838 Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 13839 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 13840 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 13841 Clockspring Assembly / Spiral Cable: Diagrams Component ID: 212 Component : MODULE-STEERING CONTROL Connector: Name : MODULE-STEERING CONTROL C1 Color : WHITE # of pins : 6 Pin Description Circuit 1 GROUND Z909 20BK 2 RADIO CONTROL MUX X20 20GY/WT 3 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 4 S/C SWITCH NO. 1 SIGNAL V37 20VT 5 S/C SWITCH RETURN V937 20VT/BR 6 HORN SWITCH SENSE X3 20DG/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 13842 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 13843 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 13844 Connector: Name : MODULE-STEERING CONTROL C2 Color : BLACK # of pins : 2 Qualifier : (PREMIUM) Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 13845 2 RADIO CONTROL MUX X20 22GY/WT 2 RADIO CONTROL MUX X20 22GY/WT Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 13846 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 13847 Connector: Name : MODULE-STEERING CONTROL C3 Color : # of pins : 4 Pin Description Circuit 1 HORN SWITCH SENSE X3 20DG/VT 2 S/C SWITCH RETURN V937 22DB/DG 2 SENSOR GROUND K900 22DB/DG 3 S/C SWITCH NO. 1 SIGNAL V37 22VT 4 S/C SWITCH NO. 2 SIGNAL V38 22VT/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 13848 Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 13849 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 13850 Connector: Name : MODULE-STEERING CONTROL C4 Color : YELLOW # of pins : 4 Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R61 20LG/VT 2 DRIVER SQUIB 2 LINE 2 R63 20LG/WT 3 DRIVER SQUIB 1 LINE 1 R43 20LG/BR 4 DRIVER SQUIB 1 LINE 2 R45 20LG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 13851 Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 13852 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 13853 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Description Clockspring Assembly / Spiral Cable: Description and Operation Description DESCRIPTION The clockspring assembly is located near the top of the steering column behind the steering wheel. Two mounting tabs (6) with round holes integral to the sides of the case are secured by two screws onto the multi-function switch mounting housing. For vehicles equipped with the Electronic Stability Program (ESP) the clockspring also includes an integral, internal Steering Angle Sensor (SAS) that is serviced as a unit with the clockspring. The clockspring consists of a flat, round molded plastic case (4) with a stubby tail that hangs below the steering column. Within the plastic case is a spool-like molded plastic rotor with a large exposed hub. The upper surface of the rotor hub has a large center hole, an engagement dowel (5), two short pigtail wires with connectors (1), and two connector receptacles (3) that face toward the steering wheel. Service replacement clocksprings are shipped pre-centered and with a molded plastic locking pin (2) that snaps into a receptacle on the rotor and is engaged with tabs on the upper surface of the clockspring case. The locking pin secures the centered clockspring rotor to the clockspring case during shipment and handling, but must be removed from the clockspring after it is installed on the steering column. The lower surface of the case (1) facing toward the instrument panel includes a locating tab (2) that is engaged by a locating pin on the multi-function switch mounting housing, two integral connector receptacles (5) and, on clocksprings with a SAS, an additional applied connector (4) with a short pigtail wire on the lower end, outboard of the two integral connector receptacles. The lower surface of the rotor hub also has a molded plastic turn signal cancel cam with two lobes (3) that is integral to the rotor. Within the plastic case and wound around the rotor spool is a long ribbon-like tape that consists of several thin copper wire leads sandwiched between two thin plastic membranes. The outer end of the tape terminates at the connector receptacles that face the instrument panel, while the inner end of the tape terminates at the pigtail wires and connector receptacles on the hub of the clockspring rotor that face the steering wheel. The clockspring cannot be repaired. If damaged, ineffective or if the driver airbag has been deployed, the clockspring must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Description > Page 13856 Clockspring Assembly / Spiral Cable: Description and Operation Operation OPERATION The clockspring is a mechanical electrical circuit component that is used to provide continuous electrical continuity between the fixed instrument panel wire harness and the electrical components mounted on or in the rotating steering wheel. On this vehicle the rotating electrical components include the driver airbag, the horn switch, the speed control switches, and the remote radio switches, if the vehicle is so equipped. The clockspring case is positioned and secured to the multi-function switch mounting housing near the top of the steering column. The connector receptacles on the tail of the fixed clockspring case connect the clockspring to the vehicle electrical system through two take outs with connectors from the instrument panel wire harness. The clockspring rotor is movable and is keyed by an engagement dowel that is molded onto the rotor hub between two fins that are cast into the lower surface of the steering wheel armature. A yellow rubber boot is installed over the engagement dowel to eliminate contact noise between the dowel and the steering wheel. The two lobes on the turn signal cancel cam on the lower surface of the clockspring rotor hub contact a turn signal cancel actuator of the multi-function switch to provide automatic turn signal cancellation. Two short, yellow-sleeved pigtail wires on the upper surface of the clockspring rotor connect the clockspring to the multistage driver airbag, while a steering wheel wire harness connects the two connector receptacles on the upper surface of the clockspring rotor to the horn switch feed pigtail wire connector and, if the vehicle is so equipped, to the optional speed control and remote radio switches on the steering wheel. Like the clockspring in a timepiece, the clockspring tape has travel limits and can be damaged by being wound too tightly during full stop-to-stop steering wheel rotation. To prevent this from occurring, the clockspring is centered when it is installed on the steering column. Centering the clockspring indexes the clockspring tape to the movable steering components so that the tape can operate within its designed travel limits. However, if the clockspring is removed from the steering column or if the steering shaft is disconnected from the steering gear, the clockspring spool can change position relative to the movable steering components. The clockspring must be re-centered following completion of this service or the tape may be damaged. Service replacement clocksprings are shipped pre-centered and with a plastic locking pin installed. This locking pin should not be removed until the clockspring has been installed on the steering column. If the locking pin is removed before the clockspring is installed on a steering column, the clockspring centering procedure must be performed. The clockspring as well as the hard wired inputs and outputs of the clockspring may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, on vehicles equipped with Electronic Stability Program (ESP) conventional diagnostic methods will not prove conclusive in the diagnosis of the Steering Angle Sensor (SAS) within the clockspring or the electronic controls or communication between other modules and devices that provide features of the ESP. The most reliable, efficient, and accurate means to diagnose the SAS or the electronic controls and communication related to ESP operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Page 13857 Clockspring Assembly / Spiral Cable: Adjustments CLOCKSPRING CENTERING WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position. 1. Place the front wheels in the straight-ahead position. 2. Remove the clockspring from the steering column. 3. Rotate the clockspring rotor (7) clockwise to the end of its travel. Do not apply excessive torque. 4. From the end of the clockwise travel, rotate the rotor about two and one-half turns counterclockwise. The engagement dowel (5) should end up at the bottom, and the airbag pigtail wires (1) and connector receptacles (3) should be at the top. Turn the rotor slightly clockwise or counterclockwise as necessary so that the slots for the clockspring locking pin (2) are in alignment. 5. The clockspring is now centered. Secure the clockspring rotor to the clockspring case to maintain clockspring centering until it is reinstalled on the steering column. 6. The front wheels should still be in the straight-ahead position. Reinstall the clockspring onto the steering column. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Removal Clockspring Assembly / Spiral Cable: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position. 1. Place the front wheels in the straight ahead position. 2. Disconnect and isolate the battery negative cable. 3. Remove the driver airbag from the steering wheel. 4. Disconnect the steering wheel wire harness connectors from the upper clockspring connector receptacles. CAUTION: Be certain that the screws that secure the steering wheel puller to the steering wheel are fully engaged in the steering wheel armature without passing through the steering wheel and damaging the clockspring. 5. Remove the steering wheel from the steering column. 6. Remove the steering column opening cover from the instrument panel. 7. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Removal > Page 13860 8. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 9. Using hand pressure, push gently inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 10. Remove the upper shroud from the lower shroud and the steering column. 11. Remove the one center screw that secures the lower shroud to the steering column (4). 12. Remove the lower shroud from the steering column. 13. Disconnect the two instrument panel wire harness connectors from the two connector receptacles located below the steering column on the back of the clockspring housing. 14. On vehicles equipped with Electronic Stability Program (ESP), disconnect the instrument panel wire harness connector from the applied connector for the Steering Angle Sensor (SAS) located below the steering column on the back of the clockspring housing. 15. Remove the two screws (2) that secure the clockspring (4) to the multi-function switch mounting housing on the steering column (3). 16. Remove the clockspring from the multi-function switch mounting housing. The clockspring cannot be repaired. It must be replaced if ineffective or damaged, or if the driver airbag has been deployed. 17. If the removed clockspring is to be reused, be certain to secure the clockspring rotor to the clockspring case to maintain clockspring centering until it is reinstalled on the steering column. If clockspring centering is not maintained, the clockspring must be centered again before it is reinstalled. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Removal > Page 13861 Clockspring Assembly / Spiral Cable: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. CAUTION: If the clockspring is not properly centered in relation to the steering wheel, steering shaft and steering gear, it may be damaged. Service replacement clocksprings are shipped pre-centered and with a locking pin installed. This locking pin should not be removed until the clockspring has been installed on the steering column. If the locking pin is removed before the clockspring is installed on a steering column, the clockspring centering procedure must be performed. NOTE: Before starting this procedure, be certain that the front wheels are still in the straight-ahead position. 1. While holding the centered clockspring rotor and case stationary in relation to each other, or with the plastic locking pin (1) installed, carefully slide the clockspring down over the steering column (3) upper shaft. 2. Align and seat the hole in the locating tab on the clockspring case over the locating pin on the multi-function switch mounting housing. 3. Install and tighten the two screws (2) that secure the clockspring to the multi-function switch mounting housing. Tighten the screws to 2 Nm (20 in. lbs.). 4. Reconnect the two instrument panel wire harness connectors to the two connector receptacles located below the steering column on the back of the clockspring housing. 5. On vehicles equipped with the Electronic Stability Program (ESP), reconnect the instrument panel wire harness connector to the applied connector for the Steering Angle Sensor (SAS) located below the steering column on the back of the clockspring housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Removal > Page 13862 6. Position the lower shroud (3) onto the steering column (4). 7. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 8. Position the upper shroud (1) onto the steering column over the lower shroud. If the vehicle is equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 9. Align the snap features on the upper shroud with the receptacles on the lower shroud and apply hand pressure to snap them together. 10. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). 11. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). 12. Reinstall the steering column opening cover onto the instrument panel. 13. If a new clockspring has been installed, remove the plastic locking pin that is securing the clockspring rotor to the clockspring case to maintain clockspring centering. NOTE: When reinstalling the steering wheel, be certain to index the engagement dowel on the upper surface of the clockspring rotor between the two fins cast into the lower surface of the steering wheel armature hub. 14. Reinstall the steering wheel onto the steering column. 15. Reconnect the steering wheel wire harness connectors to the upper clockspring connector receptacles. Be certain that the steering wheel wire harness is routed between the steering wheel back trim cover and the steering wheel armature. 16. Reinstall the driver airbag onto the steering wheel. 17. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left Impact Sensor: Locations Sensor-Front Impact-Left Component ID: 402 Component : SENSOR-FRONT IMPACT-LEFT Connector: Name : SENSOR-FRONT IMPACT-LEFT Color : YELLOW # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 2 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 13867 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 13868 Impact Sensor: Locations Sensor-Side Impact-Left 1 Component ID: 423 Component : SENSOR-SIDE IMPACT-LEFT 1 Connector: Name : SENSOR-SIDE IMPACT-LEFT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 2 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 3-4-Component Location - 58 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 13869 Component Location - 63 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 13870 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 13871 Impact Sensor: Locations Sensor-Side Impact-Right 1 Component ID: 424 Component : SENSOR-SIDE IMPACT-RIGHT 1 Connector: Name : SENSOR-SIDE IMPACT-RIGHT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 2 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 3-4-Component Location - 61 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 13872 Component Location - 64 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 13873 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left Impact Sensor: Diagrams Sensor-Front Impact-Left Component ID: 402 Component : SENSOR-FRONT IMPACT-LEFT Connector: Name : SENSOR-FRONT IMPACT-LEFT Color : YELLOW # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 2 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 13876 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 13877 Impact Sensor: Diagrams Sensor-Side Impact-Left 1 Component ID: 423 Component : SENSOR-SIDE IMPACT-LEFT 1 Connector: Name : SENSOR-SIDE IMPACT-LEFT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 2 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 3-4-Component Location - 58 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 13878 Component Location - 63 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 13879 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 13880 Impact Sensor: Diagrams Sensor-Side Impact-Right 1 Component ID: 424 Component : SENSOR-SIDE IMPACT-RIGHT 1 Connector: Name : SENSOR-SIDE IMPACT-RIGHT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 2 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 3-4-Component Location - 61 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 13881 Component Location - 64 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 13882 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Description Impact Sensor: Description and Operation Description Front FRONT Two front impact sensors (1) are used on this vehicle, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each front impact sensor is secured with a screw to the back of the right or left end of the lower radiator crossmember within the engine compartment. The sensor housing has an integral connector receptacle (4), an integral anti-rotation pin (3), and an integral mounting hole (2) with a metal sleeve to provide crush protection. The right and left front impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The front impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. The front impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Side SIDE Two side impact sensors (1) are used on this vehicle when it is equipped with the optional side curtain airbags, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each side sensor is secured with a nut within the right or left B-pillar just above the front seat belt retractors and behind the lower B-pillar trim within the passenger compartment. The sensor housing has an integral connector receptacle (2), an integral mounting stud (3), and an integral anti-rotation pin. The right and left side impact sensors are identical in construction and calibration. A cavity in the center of the molded plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The side impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Description > Page 13885 Impact Sensor: Description and Operation Operation Front FRONT The front impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the front impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to front impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Side SIDE The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through left or right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the side impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to side impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal Impact Sensor: Service and Repair Removal Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front supplemental restraints. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front supplemental restraint deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the screw (4) that secures the right or left front impact sensor (3) to the back of the right or left end of the lower radiator crossmember (1). 3. Disconnect the headlamp and dash wire harness connector (2) from the sensor connector receptacle. 4. Remove the right or left front impact sensor from the engine compartment. Side - Mega Cab SIDE - MEGA CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side curtain airbags. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 13888 1. Adjust the front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the nut (3) that secures the stud of the side impact sensor (4) to the inner B-pillar (2). 4. Reach through the large hole above the retractor mounting hole in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 5. Pull the side impact sensor out through the large hole in the B-pillar far enough to access and disconnect the body wire harness connector (1) from the sensor connector receptacle. 6. Remove the side impact sensor from the B-pillar. Side - Quad Cab SIDE - QUAD CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side curtain airbags. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 13889 1. Adjust the front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the nut (3) that secures the stud of the side impact sensor (2) to the inner B-pillar (1). 4. Reach through the large hole above the retractor mounting hole in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 5. Pull the side impact sensor out through the large hole in the B-pillar far enough to access and disconnect the body wire harness connector (4) from the sensor connector receptacle. 6. Remove the side impact sensor from the B-pillar. Side - Standard Cab SIDE - STANDARD CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side curtain airbags. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. 1. Adjust the driver or passenger side front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the front outboard seat belt and retractor from the inside of the B-pillar. 4. Remove the nut (4) that secures the stud of the side impact sensor (1) to the inner B-pillar. 5. Reach through the retractor mounting hole (3) in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 6. Pull the side impact sensor out of the B-pillar far enough to access and disconnect the body wire harness connector (2) from the sensor connector receptacle. 7. Remove the sensor from the B-pillar. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 13890 Impact Sensor: Service and Repair Installation Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front supplemental restraints. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front supplemental restraint deployment. 1. Position the right or left front impact sensor (3) into the engine compartment. 2. Reconnect the headlamp and dash wire harness connector (2) to the sensor connector receptacle. 3. Carefully position the sensor onto the back of the right or left end of the lower radiator crossmember (1). Be certain that the anti-rotation pin on the back of the sensor is engaged in the clearance hole of the crossmember. 4. Install and tighten the screw (4) that secures the sensor to the back of the crossmember. Tighten the screw to 10 Nm (90 in. lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Side - Mega Cab SIDE - MEGA CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side curtain airbags. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 13891 1. Position the side impact sensor (4) to the large hole above the retractor mounting hole in the inner B-pillar (2). 2. Reconnect the body wire harness connector (1) to the sensor connector receptacle. 3. Reach through the large hole above the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (3) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 Nm (70 in. lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Side - Quad Cab SIDE - QUAD CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side curtain airbags. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. 1. Position the side impact sensor (2) to the large hole above the retractor mounting hole in the inner B-pillar (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 13892 2. Reconnect the body wire harness connector (4) to the sensor connector receptacle. 3. Reach through the large hole above the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (3) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 Nm (70 in. lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Side - Standard Cab SIDE - STANDARD CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side curtain airbags. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. 1. Position the side impact sensor (1) to the retractor mounting hole (3) in the inner B-pillar. 2. Reconnect the body wire harness connector (2) to the sensor connector receptacle. 3. Reach through the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (4) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 Nm (70 in. lbs.). 5. Reinstall the front outboard seat belt and retractor to the inside of the B-pillar. 6. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Description and Operation > Description Seat Position Sensor: Description and Operation Description DESCRIPTION The seat track position sensor (2) is a Hall Effect-type sensor used on some vehicles. This sensor consists of a Hall Effect Integrated Circuit (IC) chip encased in potting material within a cavity of the molded plastic sensor housing. The sensor housing has a mounting slot containing an integral latch feature (1) and slides and latches onto a stamped metal blade-type bracket located on the inboard side of the upper inboard seat adjuster track near the rear of the driver side front seat. A molded connector receptacle (3) integral to the sensor housing is connected to the vehicle electrical system through a connector and take out of the driver seat wire harness beneath the front seat cushion frame. The seat track position sensor cannot be adjusted or repaired and, if ineffective or damaged, the entire sensor must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Description and Operation > Description > Page 13897 Seat Position Sensor: Description and Operation Operation OPERATION The seat track position sensor is designed to provide a seat position data input to the Occupant Restraint Controller (ORC) indicating whether the driver side front seat is in a full forward or a not full forward position. The ORC uses this data as an additional logic input for use in determining the appropriate deployment force to be used when deploying the multistage driver side front airbag. The seat track position sensor receives a nominal five volt supply from the ORC. The sensor communicates the seat position by modulating the voltage returned to the ORC on a sensor data circuit. The ORC also monitors the condition of the sensor circuits and will store a Diagnostic Trouble Code (DTC) for any fault that is detected, and sends messages over the Controller Area Network (CAN) data bus to illuminate the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The hard wired circuits between the seat track position sensor and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the seat track position sensor or the electronic controls and communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the seat track position sensor or the electronic controls and communication related to seat track position sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Service and Repair > Removal Seat Position Sensor: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Reach under the front seat cushion to access the seat track position sensor (2) on a bracket (1) located on the inboard side near the rear of the upper inboard driver seat track (4). 3. Using a small screwdriver, hold the latch feature (3) depressed while sliding the connector end of the sensor off of the bracket. 4. Disconnect the seat wire harness connector (5) from the sensor connector receptacle. 5. Remove the sensor from under the front seat. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Service and Repair > Removal > Page 13900 Seat Position Sensor: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Reach under the driver side front seat cushion to reconnect the seat wire harness connector (5) to the seat track position sensor (2) connector receptacle. Be certain that the latch on the connector is fully engaged. 2. Align the open end of the sensor to the slide tab of the sensor bracket (1) located on the inboard side near the rear of the upper inboard driver seat track (4). 3. Push the sensor firmly onto the bracket until the latch feature (3) snaps into place with an audible click. 4. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation > Description Malfunction Lamp / Indicator: Description and Operation Description DESCRIPTION An airbag indicator is standard equipment on all instrument clusters. However, the instrument cluster can be programmed to disable this indicator on vehicles that are not equipped with the airbag system, which is not available in some markets. This indicator is located near the upper edge of the instrument cluster, between the tachometer and the speedometer. The airbag indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Airbag in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The airbag indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation > Description > Page 13905 Malfunction Lamp / Indicator: Description and Operation Operation OPERATION The airbag indicator gives an indication to the vehicle operator when the airbag system, or a circuit or component of the system is ineffective. The airbag indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Occupant Restraint Controller (ORC) over the Controller Area Network (CAN) data bus. The airbag indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the airbag indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the airbag indicator is illuminated for about six to eight seconds. The entire bulb test is a function of the ORC. - Airbag Indicator Lamp-On Message - Each time the cluster receives an electronic airbag indicator lamp-ON message from the ORC, the airbag indicator will be illuminated. The indicator remains illuminated for about twelve seconds or until the cluster receives a lamp-OFF message from the ORC, whichever is longer. This indicator will also be extinguished when the ignition switch is turned to the OFF position. Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the ORC for 10 consecutive message cycles, the airbag indicator is illuminated. The indicator remains illuminated until the cluster receives a single lamp-OFF message from the ORC. - Actuator Test - Each time the cluster is put through the actuator test, the airbag indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The actuator test illumination of the airbag indicator is a function of the instrument cluster. The ORC continually monitors the airbag system circuits and sensors to decide whether the system is in good operating condition. The ORC then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the ORC sends a lamp-ON message after the bulb test, it indicates that the ORC has detected a system malfunction or that the airbags and seat belt tensioners may not deploy when required, or may deploy when not required. The ORC will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the airbag indicator fails to illuminate due to an open or short in the cluster airbag indicator circuit, the cluster sends a message notifying the ORC of the condition, the instrument cluster and the ORC will each store a DTC, and the cluster will flash the seatbelt indicator ON and OFF as a backup to notify the vehicle operator. For proper diagnosis of the airbag system, the ORC, the EMIC, the CAN data bus or the electronic communication related to airbag indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Component ID: 208 Component : MODULE-OCCUPANT RESTRAINT CONTROLLER Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C1 Color : YELLOW # of pins : 24 Pin Description Circuit 1-2-3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT 5-6 PASSENGER AIRBAG INDICATOR DRIVER G104 20VT/GY 7 PASSENGER AIRBAG MUX SWITCH RETURN R104 20LB/LG 8 PASSENGER AIRBAG MUX SWITCH SENSE R106 20LG/LB 9 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 10 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT 11 RIGHT FRONT IMPACT SENSOR GROUND R82 20WT/LB 12 RIGHT FRONT IMPACT SENSOR SIGNAL R80 20VT/LB 13 - 14 - 15 - 16 - 17 DRIVER SQUIB 1 LINE 1 R43 20LG/BR 18 DRIVER SQUIB 1 LINE 2 R45 20LG/OR 19 PASSENGER SQUIB 1 LINE 2 R44 20LB/OR 20 PASSENGER SQUIB 1 LINE 1 R42 20LB/BR 21 DRIVER SQUIB 2 LINE 1 R61 20LG/VT 22 DRIVER SQUIB 2 LINE 2 R63 20LG/WT 23 PASSENGER SQUIB 2 LINE 1 R64 20LB/WT 24 PASSENGER SQUIB 2 LINE 2 R62 20LB/VT Component Location - 58 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 13910 Component Location - 63 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 13911 Component Location - 51 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 13912 Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C2 Color : YELLOW # of pins : 32 Pin Description Circuit 1 RIGHT CURTAIN SQUIB 1 LINE 2 R2 20WT/LB 2 RIGHT CURTAIN SQUIB 1 LINE 1 R4 20OR/LB 3 LEFT CURTAIN SQUIB 1 LINE 1 R3 20LB/OR 4 LEFT CURTAIN SQUIB 1 LINE 2 R1 20LB/WT 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 13913 6-7-8-9 DRIVER SEAT BELT TENSIONER LINE 2 R53 20LG/YL 10 DRIVER SEAT BELT TENSIONER LINE 1 R55 20LG/DG 11 PASSENGER SEAT BELT TENSIONER LINE 1R56 20LB/DG 12 PASSENGER SEAT BELT TENSIONER LINE 2R54 20LB/YL 13 LEFT CURTAIN SQUIB 1 LINE 2 R1 20LB/WT 14 LEFT CURTAIN SQUIB 1 LINE 1 R3 20LB/OR 15 RIGHT CURTAIN SQUIB 1 LINE 1 R4 20OR/LB 16 RIGHT CURTAIN SQUIB 1 LINE 2 R2 20WT/LB 17 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 18 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20PK/VT 19 - 20 GROUND Z104 18BK/LG 21 - 22 - 23 - 24 - 25 DRIVER SEAT POSITION SENSOR DATA R261 20LB/TN 26 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/GY 27 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 28 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 29 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 30 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 31 - 32 - Component Location - 58 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 13914 Component Location - 63 Component Location - 51 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 13915 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 13916 Air Bag Control Module: Diagrams Component ID: 208 Component : MODULE-OCCUPANT RESTRAINT CONTROLLER Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C1 Color : YELLOW # of pins : 24 Pin Description Circuit 1-2-3 CAN B BUS (+) D55 20WT/OR 4 CAN B BUS (-) D54 20WT 5-6 PASSENGER AIRBAG INDICATOR DRIVER G104 20VT/GY 7 PASSENGER AIRBAG MUX SWITCH RETURN R104 20LB/LG 8 PASSENGER AIRBAG MUX SWITCH SENSE R106 20LG/LB 9 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 10 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT 11 RIGHT FRONT IMPACT SENSOR GROUND R82 20WT/LB 12 RIGHT FRONT IMPACT SENSOR SIGNAL R80 20VT/LB 13 - 14 - 15 - 16 - 17 DRIVER SQUIB 1 LINE 1 R43 20LG/BR 18 DRIVER SQUIB 1 LINE 2 R45 20LG/OR 19 PASSENGER SQUIB 1 LINE 2 R44 20LB/OR 20 PASSENGER SQUIB 1 LINE 1 R42 20LB/BR 21 DRIVER SQUIB 2 LINE 1 R61 20LG/VT 22 DRIVER SQUIB 2 LINE 2 R63 20LG/WT 23 PASSENGER SQUIB 2 LINE 1 R64 20LB/WT 24 PASSENGER SQUIB 2 LINE 2 R62 20LB/VT Component Location - 58 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 13917 Component Location - 63 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 13918 Component Location - 51 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 13919 Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C2 Color : YELLOW # of pins : 32 Pin Description Circuit 1 RIGHT CURTAIN SQUIB 1 LINE 2 R2 20WT/LB 2 RIGHT CURTAIN SQUIB 1 LINE 1 R4 20OR/LB 3 LEFT CURTAIN SQUIB 1 LINE 1 R3 20LB/OR 4 LEFT CURTAIN SQUIB 1 LINE 2 R1 20LB/WT 5-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 13920 6-7-8-9 DRIVER SEAT BELT TENSIONER LINE 2 R53 20LG/YL 10 DRIVER SEAT BELT TENSIONER LINE 1 R55 20LG/DG 11 PASSENGER SEAT BELT TENSIONER LINE 1R56 20LB/DG 12 PASSENGER SEAT BELT TENSIONER LINE 2R54 20LB/YL 13 LEFT CURTAIN SQUIB 1 LINE 2 R1 20LB/WT 14 LEFT CURTAIN SQUIB 1 LINE 1 R3 20LB/OR 15 RIGHT CURTAIN SQUIB 1 LINE 1 R4 20OR/LB 16 RIGHT CURTAIN SQUIB 1 LINE 2 R2 20WT/LB 17 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 18 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20PK/VT 19 - 20 GROUND Z104 18BK/LG 21 - 22 - 23 - 24 - 25 DRIVER SEAT POSITION SENSOR DATA R261 20LB/TN 26 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/GY 27 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 28 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 29 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 30 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 31 - 32 - Component Location - 58 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 13921 Component Location - 63 Component Location - 51 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 13922 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Description Air Bag Control Module: Description and Operation Description DESCRIPTION The Occupant Restraint Controller (ORC) (1) is located in the passenger compartment of the vehicle, where it is secured by three nuts to three studs on a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel under the center front seat or the center floor console, as the vehicle is equipped. Concealed within a hollow in the center of the die cast aluminum ORC housing is the electronic circuitry of the ORC which includes a microprocessor, an electronic impact sensor, an electronic safing sensor, and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ORC housing with screws to enclose and protect the internal electronic circuitry and components. An arrow (2) printed on the label (3) on the top of the ORC housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ORC housing has integral mounting flanges on three corners. The mounting flange to the right of the connector receptacles (4) has an integral locating pin on its lower surface. Both right side flanges have round mounting holes, while the flange on the left side has a slotted mounting hole. A molded plastic electrical connector (4) with 2 receptacles, one containing 24 terminal pins and the other containing 32 terminal pins, exits the forward facing side of the ORC housing. These terminal pins connect the ORC to the vehicle electrical system through two dedicated take outs and connectors, one each from the instrument panel and the body wire harnesses. A molded plastic protective cover is installed over the ORC to provide additional moisture contamination protection to the unit. Integral latch features on each side of the cover engage a slot (5) on each side of the base of the ORC housing to secure the cover to the ORC. This protective cover must be reinstalled following any service requiring its removal. The impact sensor and safing sensor internal to the ORC are calibrated for the specific vehicle, and are only serviced as a unit with the ORC. In addition, there are unique versions of the ORC for light and heavy-duty vehicles, and for vehicles with or without the optional side curtain airbags. The ORC cannot be repaired or adjusted and, if damaged or ineffective, it must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Description > Page 13925 Air Bag Control Module: Description and Operation Operation OPERATION The microprocessor in the Occupant Restraint Controller (ORC) contains the supplemental restraint system logic circuits and controls all of the supplemental restraint system components. The ORC uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Controller Area Network (CAN) data bus. This method of communication is used for control of the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) and for supplemental restraint system diagnosis and testing through the 16-way Data Link Connector (DLC) located on the driver side lower edge of the instrument panel. The ORC microprocessor continuously monitors all of the supplemental restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC over the CAN data bus to turn ON the airbag indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the ORC. For some DTCs, if a fault does not recur for a number of ignition cycles, the ORC will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. In standard cab vehicles, the ORC also monitors a resistor multiplexed input from the passenger airbag on/off switch. If the passenger airbag on/off switch is set to the OFF position, the ORC turns ON the passenger airbag on/off indicator and will internally disable the passenger airbag and seat belt tensioner from being deployed. The ORC receives battery current through two circuits; a fused ignition switch output (run) circuit through a fuse in the Totally Integrated Power Module (TIPM), and a fused ignition switch output (run-start) circuit through a second fuse in the TIPM. The ORC receives ground through a ground circuit and take out of the instrument panel wire harness. This take out has a single eyelet terminal connector that is secured by a ground screw to the instrument panel structural support. These connections allow the ORC to be operational whenever the ignition switch is in the START or ON positions. The ORC also contains an energy-storage capacitor. When the ignition switch is in the START or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the supplemental restraint components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup supplemental restraint system protection in case there is a loss of battery current supply to the ORC during an impact. Two sensors are contained within the ORC, an electronic impact sensor and a safing sensor. The ORC also monitors inputs from two remote front impact sensors located on the back of the right and left ends of the lower radiator crossmember near the front of the vehicle. The electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provide verification of the direction and severity of an impact. On vehicles equipped with optional side curtain airbags the ORC also monitors inputs from two additional remote impact sensors located within both the left and right B-pillars to control deployment of the side curtain airbag units. The safing sensor is an electronic accelerometer sensor within the ORC that provides an additional logic input to the ORC microprocessor. The safing sensor is used to verify the need for a supplemental restraint deployment by detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags to deploy. Vehicles equipped with optional side curtain airbags feature a second safing sensor within the ORC to provide confirmation to the ORC microprocessor of side impact forces. This second safing sensor is a bi-directional unit that detects impact forces from either side of the vehicle. Pre-programmed decision algorithms in the ORC microprocessor determine when the deceleration rate as signaled by the impact sensors and the safing sensors indicate an impact that is severe enough to require supplemental restraint system protection and, based upon the severity of the monitored impact, determines the level of front airbag deployment force required for each front seating position. When the programmed conditions are met, the ORC sends the proper electrical signals to deploy the dual multistage front airbags at the programmed force levels, the front seat belt tensioners and, if the vehicle is so equipped, either side curtain airbag unit. On standard cab vehicles, the passenger front airbag and seat belt tensioner will be deployed by the ORC only if enabled by the passenger airbag on/off switch at the time of the impact. The hard wired inputs and outputs for the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ORC or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the ORC or the electronic controls and communication related to ORC operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal Air Bag Control Module: Service and Repair Removal Module MODULE WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the occupant restraint controller, as it can damage the impact sensor or affect its calibration. The occupant restraint controller contains the impact sensor, which enables the system to deploy the supplemental restraints. If an occupant restraint controller is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the protective cover from the Occupant Restraint Controller (ORC) (1). 3. Unlatch and disconnect the two wire harness connectors (3) for the ORC from the ORC connector receptacles (2 and 4) located on the forward facing side of the module. To disconnect the wire harness connectors from the ORC, depress the release tab and lift the lever arm on each connector. 4. Remove the three nuts (2) that secure the ORC (1) to the studs on the ORC mounting bracket (3) on the floor panel transmission tunnel. 5. Remove the ORC from the floor panel transmission tunnel. Cover Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal > Page 13928 COVER WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. NOTE: The front seat assembly must be unfastened from the floor panel, but need not be removed from the vehicle for access to the Occupant Restraint Controller (ORC) cover for service. 2. Remove the front seat from the vehicle. 3. Using a trim stick or another suitable wide flat-bladed tool, gently pry the latch feature on either side of the ORC cover (1) away from the base of the ORC (2) far enough to disengage the cover from the module. 4. Remove the ORC cover from over the ORC. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal > Page 13929 Air Bag Control Module: Service and Repair Installation Module MODULE WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the occupant restraint controller, as it can damage the impact sensor or affect its calibration. The occupant restraint controller contains the impact sensor, which enables the system to deploy the supplemental restraints. If an occupant restraint controller is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. 1. Position the Occupant Restraint Controller (ORC) (1) over the three studs of the ORC mounting bracket (3) on the floor panel transmission tunnel, then engage the locating pin on the bottom of the right ORC mounting flange into the locating hole in the bracket. When the ORC is correctly positioned, the arrow on the ORC label will be pointed forward in the vehicle. 2. Install and tighten the three nuts (2) that secure the ORC to the bracket on the floor panel transmission tunnel. Tighten the nuts to 10 Nm (7 ft. lbs.). 3. Reconnect the two wire harness connectors (3) for the ORC (1) to the ORC connector receptacles (2 and 4) located on the forward facing side of the module. Be certain that the latches on the connectors are each fully engaged. 4. Reinstall the ORC cover onto the ORC. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal > Page 13930 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Cover COVER WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the ORC cover (1) over the Occupant Restraint Controller (ORC) (2). 2. Align the latch feature on each side of the ORC cover with the notch in each side at the base of the ORC housing. 3. Using hand pressure, press firmly and evenly downward on the ORC cover until each latch feature is fully engaged with the ORC housing. 4. Reinstall the front seat into the vehicle. 5. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation Air Bag(s) Arming and Disarming: Technical Service Bulletins Air Bag System - Passenger Air Bag Deactivation NUMBER: 08-001-07 REV. B GROUP: Electrical DATE: May 16, 2007 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED. THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION. DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION. SUBJECT: Passenger Air Bag Deactivation MODELS: 2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 0300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakoka 2006 - 2007 (DR) Ram Truck 2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 13936 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet. NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States. PARTS REQUIRED: POLICY: Information Only Disclaimer: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 13937 This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Description Child Seat Tether Attachment: Description and Operation Description DESCRIPTION This vehicle is equipped with a Lower Anchors and Tether for Children, or LATCH child restraint anchorage system. The LATCH system provides for the installation of suitable child restraints in certain seating positions without using the standard equipment seat belt provided for that seating position. Standard cab vehicles are equipped with a fixed-position child restraint upper tether anchor for the front center and outboard seating positions (2), and child restraint lower anchors for the front outboard seating position (1). Quad cab vehicles are equipped with a fixed-position child restraint upper tether anchor strap for the rear center and both rear outboard seating positions (2), and child restraint lower anchors for both rear outboard seating positions (1). All front seat child restraint anchors are deleted on quad cabs. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Description > Page 13943 Mega cab vehicles are also equipped with a fixed-position child restraint upper tether anchor strap for the rear center and both rear outboard seating positions (2), but have child restraint lower anchors for all three rear seating positions (1). As on quad cabs, all front seat child restraint anchors are deleted on mega cab vehicles. The two upper tether anchors (3) for standard cabs are integral to the upper cab back panel reinforcement and are concealed behind individual trim cover and bezel units (1) that are integral to the cab back trim panel (2). These upper tether anchors cannot be adjusted or repaired and, if ineffective or damaged, they must be replaced as a unit with the upper cab back panel reinforcement. The upper tether anchor trim covers and bezels are serviced as a unit with the cab back trim panel. The three upper tether anchor straps (1) for quad cab and mega cab vehicles are secured to the upper cab back panel (2) reinforcement with screws (3). These anchor straps are concealed behind the upright rear seat back. The upper tether anchor straps are available for individual service replacement. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Description > Page 13944 The lower anchors (2) for all vehicles are integral to their respective front or rear seat cushion frame. Round markers (3) with an imprinted child seat icon on the standard cab front seat back trim cover helps identify the anchor locations for that application because they may be otherwise difficult to see with the seat back in the upright position. These lower anchors are each constructed from round steel bar stock that is formed into a U-shape, then securely welded at each end to the seat cushion frame. They are each accessed from the front of their respective seats, at each side where the seat back meets the seat cushion. These lower anchors cannot be adjusted or repaired and, if ineffective or damaged, they must be replaced as a unit with the seat cushion frame. On quad cab or mega cab vehicles, if the rear seat lower anchors (2) have been bent or broken as a result of a vehicle collision, the latch for the affected rear seat cushion frame unit must also be replaced. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Description > Page 13945 Child Seat Tether Attachment: Description and Operation Operation OPERATION See the owner's manual in the vehicle glove box for the proper use of all of the factory-installed child restraint anchors. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Removal Child Seat Tether Attachment: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: The following procedure applies only to the rear seat upper child tether straps used on quad cab vehicles. The child restraint anchors used in other vehicles and locations are integral to other components and cannot be serviced separately. 1. Remove the rear seat from the vehicle. 2. Remove the screw (3) that secures the child tether strap (1) to the upper cab back panel (2) reinforcement. 3. Remove the child tether strap from the upper cab back panel reinforcement. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Removal > Page 13948 Child Seat Tether Attachment: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: The following procedure applies only to the rear seat upper child tether straps used on quad cab vehicles. The child restraint anchors used in other vehicles and locations are integral to other components and cannot be serviced separately. 1. Position the child tether strap (1) onto the cab back panel (2) upper reinforcement. 2. Install and tighten the screw (3) that secures the child tether strap to the upper cab back panel reinforcement. Tighten the screw to 14 Nm (10 ft. lbs.). 3. Reinstall the rear seat into the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Description and Operation > Description Seat Belt: Description and Operation Description DESCRIPTION The seat belt retractors used in all seating positions include an inertia-type, emergency locking mechanism (7) as standard equipment. However, the retractor locking mechanisms for all seating positions except the driver side front position are mechanically switchable from an emergency locking retractor to an automatic locking retractor. The primary function of this feature is to securely accommodate a child seat in any seating position of the vehicle without the need for a self-cinching seat belt tip half latch plate unit or another supplemental device that would be required to prevent the seat belt webbing from unwinding freely from the retractor spool of an inertia-type emergency locking retractor mechanism. The automatic locking mechanism is integral to the seat belt and retractor unit and is concealed beneath a molded plastic cover located on one side of the retractor spool. The automatic locking mechanism cannot be adjusted or repaired and, if ineffective or damaged, the entire passenger side front seat belt and retractor unit must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Description and Operation > Description > Page 13953 Seat Belt: Description and Operation Operation OPERATION The locked mode of the automatic locking retractor is engaged and the retractor is switched from operating as a standard inertia-type emergency locking retractor by first buckling the combination lap and shoulder belt buckle. Then grasp the shoulder belt and pull all of the webbing out of the retractor. Once all of the belt webbing is extracted from the spool, the retractor will automatically become engaged in the pre-locked automatic locking mode and will make a light, audible clicking or ratcheting sound as the shoulder belt is allowed to retract to confirm that the automatic locking mode is now engaged. Once the automatic locking mode is engaged, the retractor will remain locked and the belt will remain tight around whatever it is restraining. The retractor is returned to standard emergency locking (inertia) mode by unbuckling the combination lap and shoulder belt buckle and allowing the belt webbing to be almost fully retracted onto the retractor spool. The emergency locking mode is confirmed by the absence of the light, audible clicking or ratcheting sound as the belt webbing retracts. This mode will allow the belt to unwind from and wind onto the retractor spool freely unless and until a predetermined inertia load is sensed, or until the retractor is again switched to the automatic locking mode. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt Seat Belt: Service and Repair Seat Belt Removal REMOVAL WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: A fixed position front center seat belt buckle is located on the left side of the front center seat (20 percent) used on all vehicles. Standard cab vehicles have a unique, fixed position, black, keyed, lower anchor buckle for the three-point center seat belt lower anchor located on the right side of the front center seat section. Quad cab and mega cab vehicles have a fixed position front center seat lap belt located on the right side of the front center seat section. The following procedure applies to the front center seating position belt buckle, the lap belt or the anchor buckle. The three-point front center seat belt and retractor unit is only used on standard cab vehicles. 1. Move the adjacent right or left front outboard seat (40 percent) to its most forward position and tilt the seat back forward for easiest access to the lower anchor of the front center seat belt buckle, lap belt or anchor buckle (1). 2. On standard cab vehicles only, remove the stowage tray from the rear floor panel behind the seat. 3. From behind the front seat, remove the screw (5) that secures the lower anchor of the front center seat belt buckle, lap belt or anchor buckle to the center seat support bracket (3). 4. From the front of the front seat, reach between the side of the center seat cushion (6) and the adjacent right or left front outboard seat cushion to access and remove the seat belt buckle, lap belt or anchor buckle through the elastic strap (2) on the side of the center seat cushion. 5. Remove the front center seat belt buckle, lap belt or anchor buckle unit from the front seat. Installation INSTALLATION WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: A fixed position front center seat belt buckle is located on the left side of the front center seat (20 percent) used on all vehicles. Standard cab Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 13956 vehicles have a unique, fixed position, black, keyed, lower anchor buckle for the three-point center seat belt lower anchor located on the right side of the front center seat section. Quad cab and mega cab vehicles have a fixed position front center seat lap belt located on the right side of the front center seat section. The following procedure applies to the front center seating position belt buckle, the lap belt or the anchor buckle. The three-point front center seat belt and retractor unit is only used on standard cab vehicles. 1. From the front of the front seat, position the front center seat belt buckle, lap belt or anchor buckle unit (1) through the elastic strap (2) on the side of the center seat cushion (6). 2. From the front of the front seat, reach between the side of the center seat cushion and the adjacent right or left front outboard seat cushion to route the lower anchor of the seat belt buckle, lap belt or anchor buckle unit down between the side of the center seat cushion and the adjacent right or left front outboard seat cushion. Be certain that the belt webbing is not twisted. 3. From behind the front seat, position the lower anchor of the seat belt buckle, lap belt or anchor buckle to the center seat support bracket (3). Be certain to engage the anti-rotation tab on the lower anchor into the corresponding hole in the center seat support bracket. 4. Install and tighten the screw (5) that secures the lower anchor of the seat belt buckle, lap belt or anchor buckle to the center seat support bracket. Tighten the screw to 40 Nm (29 ft. lbs.). 5. On standard cab vehicles only, reinstall the stowage tray onto the rear floor panel behind the seat. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 13957 Seat Belt: Service and Repair Seat Belt And Retractor Front Center - Standard Cab FRONT CENTER - STANDARD CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: A front center seat belt and retractor is used only on standard cab vehicles. Quad cab and mega cab vehicles have a lap belt in the front center seating position. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. 1. Reach between the center of the front seat cushion and front seat back to access and unbuckle the front center seat belt lower anchor latch plate from the unique black, keyed lower anchor buckle. Use an ignition key or a small screwdriver to depress the small white release button on the anchor buckle. 2. Move the front seat to its most forward position for easiest access to the front center seat belt and retractor unit. 3. Remove the stowage tray from the rear floor panel behind the seat. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry at each side of the front center seat belt bezel (5) on the cab back trim panel (1) to release the snap features that secure the bezel to the panel. 5. Remove the bezel from the webbing of the front center seat belt (4). 6. Remove the trim from the cab back panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 13958 7. Remove the two screws (3) that secure the belt bracket (2) of the front center seat belt (7) to the body bracket (1) on the upper cab back panel (8) reinforcement. 8. Remove the belt bracket of the front center seat belt from the body bracket on the upper cab back panel reinforcement. 9. Remove the two screws (4) that secure the front center seat belt retractor bracket (5) to the floor panel (6) near the base of the cab back panel. 10. Remove the front center seat belt and retractor unit from the floor panel. Front Outboard - Quad And Mega Cab FRONT OUTBOARD - QUAD AND MEGA CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. NOTE: The following procedure is for replacement of an ineffective or damaged seat belt and retractor unit. The front retractor also includes a seat belt tensioner. If the front seat belt or retractor is ineffective or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the unit from the vehicle. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 13959 1. Adjust the front seat to its most forward position for easiest access to the front seat belt (2) lower anchor cover (4) and the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Grasp the upper edge of the lower anchor cover and pull upward to unsnap it from the front seat cushion outboard side shield. 4. Remove the screw (3) that secures the lower anchor to the outboard side of the front seat cushion frame. 5. Unsnap the trim cover (3) from the front seat belt turning loop (5) and discard. 6. Remove the screw (4) that secures the seat belt turning loop to the height adjuster (1) on the upper B-pillar. 7. Remove the seat belt turning loop from the height adjuster. 8. Remove the upper trim (2) from the inside of the B-pillar. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 13960 9. Remove the lower trim (3) from the inside of the B-pillar.. 10. Disconnect the yellow body wire harness connector (5) from the seat belt tensioner initiator on the retractor (7). 11. Disengage the two clips that secure the belt web guide (1) to the B-pillar. 12. Remove the screw (4) that secures the upper retractor bracket to the B-pillar. 13. Remove the screw (6) that secures the lower retractor bracket to the B-pillar. 14. Disengage the locating tab on the upper retractor bracket from the hole in the inner B-pillar. 15. Remove the front outboard seat belt and retractor from the B-pillar as a unit. Front Outboard - Standard Cab FRONT OUTBOARD - STANDARD CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. NOTE: The following procedure is for replacement of an ineffective or damaged seat belt and retractor unit. The front retractor also includes a seat belt tensioner. If the front seat belt or retractor is ineffective or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the unit from the vehicle. NOTE: The seat belt retractor on the driver side of all standard cab vehicles includes a tension reducer. All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 13961 1. Adjust the front seat (1) to its most forward position for easiest access to the front seat belt (2) lower anchor cover (4) and the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the stowage tray from the rear floor panel behind the seat. 4. Grasp the upper edge of the lower anchor cover and pull upward to unsnap it from the front seat cushion outboard side shield. 5. Remove the screw (3) that secures the lower anchor to the outboard side of the front seat cushion frame. 6. Unsnap the trim cover (3) from the front seat belt turning loop (5) and discard. 7. Remove the screw (4) that secures the seat belt turning loop to the height adjuster (1) on the upper B-pillar. 8. Remove the seat belt turning loop from the height adjuster. 9. Remove the upper trim (2) from the inside of the B-pillar. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 13962 10. Remove the lower trim (3) from the inside of the B-pillar. 11. Disconnect the yellow body wire harness connector (5) from the seat belt tensioner initiator on the retractor (7). 12. On the driver side only, disconnect the white body wire harness connector from the connector receptacle for the seat belt tension reducer located near the bottom of the retractor. 13. Disengage the two clips that secure the belt web guide (1) to the B-pillar. 14. Remove the screw (4) that secures the upper retractor bracket to the B-pillar. 15. Remove the screw (6) that secures the lower retractor bracket to the B-pillar. 16. Disengage the locating tab on the upper retractor bracket from the hole in the inner B-pillar. 17. Remove the front outboard seat belt and retractor from the B-pillar as a unit. Rear Center - Mega Cab REAR CENTER - MEGA CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. 1. Fold the 60 percent section of the rear seat back (2) down onto the seat cushion in the cargo storage position, then lift and prop open the seat back Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 13963 filler panel (3) as necessary for easiest access to the rear center seat belt lower anchor and right outboard buckle anchor bracket. 2. Remove the screw (7) that secures the center seat belt lower anchor to the anchor bracket (3) and, from the front of the seat back, pull the belt lower anchor out from between the seat back (1) and the seat cushion (2). 3. Remove the two screws (3) that secure the bezel (2) to the top of the 60 percent section of the rear seat back (1). 4. Remove the bezel from the webbing of the rear center seat belt. 5. Remove the trim cover from the 60 percent section of the rear seat back. 6. Remove the two screws (6) that secure the belt bracket (1) of the rear center seat belt to the top of the seat back frame (3). 7. Disengage the belt bracket of the rear center seat belt from the seat back frame. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 13964 8. Remove the screw (4) that secures the rear center seat belt retractor to the seat back frame. 9. Remove the seat belt and retractor from the rear seat back as a unit. Rear Center - Quad Cab REAR CENTER - QUAD CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: The rear center seat belt and retractor is secured to a mounting bracket that includes the right outboard occupant seat belt buckle. The rear right outboard occupant buckle is available for service only as a unit with the center seat belt and retractor. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. 1. Lift up the rear seat cushion into its stowed position against the rear seat back. 2. Remove the screw (5) that secures the center seat belt lower anchor and the left side of the seat belt retractor mounting bracket to the rear floor panel. 3. Remove the rear seat from the vehicle. On vehicles with the optional 60/40 split rear bench, only the 60 percent section (right side) of the rear seat must be removed. 4. Lift upward on the forward edge of the rear center seat belt bezel (2) at the top of the cab back panel (1) to release the snap features that secure the bezel to the belt bracket. 5. Remove the bezel from the webbing of the rear center seat belt. 6. Lift the rear center seat belt cover (3) off of the belt bracket at the top of the cab back panel and remove the cover from the webbing of the rear center seat belt. 7. Remove the two screws (4) that secure the belt bracket of the rear center seat belt to the body bracket on the upper cab back panel reinforcement. 8. Remove the belt bracket of the rear center seat belt from the body bracket. 9. Remove the screw (7) that secures the right side of the seat belt retractor mounting bracket and the right outboard occupant buckle (6) unit to the rear floor panel near the base of the cab back panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 13965 10. Remove the rear center seat belt and retractor unit from the vehicle. Rear Outboard - Mega Cab REAR OUTBOARD - MEGA CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. 1. Remove the rear seat from the vehicle. 2. Remove the screw (6) that secures the seat belt lower anchor (7) to the base of the inner C-pillar. 3. Unsnap the trim cover (4) from the front seat belt turning loop (3) and discard. 4. Remove the screw (5) that secures the seat belt turning loop to the height adjuster (1) on the upper C-pillar. 5. Remove the seat belt turning loop from the height adjuster. 6. Remove the upper trim (2) from the inside of the C-pillar. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 13966 7. Remove the lower trim (2) from the inside of the C-pillar. 8. Disengage the two clips that secure the belt web guide (5) to the C-pillar. 9. Remove the screw (3) that secures the lower bracket of the retractor (4) to the C-pillar. 10. Disengage the hooks on the upper retractor bracket from the slots in the C-pillar above the retractor mounting hole. 11. Remove the rear outboard seat belt and retractor from the C-pillar as a unit. Rear Outboard - Quad Cab REAR OUTBOARD - QUAD CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. 1. Remove the rear seat from the vehicle. 2. Remove the screw (5) that secures the seat belt lower anchor (6) to the base of the inner C-pillar. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 13967 3. Unsnap the trim cover (3) from the front seat belt turning loop (2) and discard. 4. Remove the screw (4) that secures the seat belt turning loop to the upper C-pillar. 5. Remove the seat belt turning loop from the upper C-pillar. 6. Remove the upper trim (1) from the inside of the C-pillar. 7. Remove the lower trim (2) from the inside of the C-pillar. 8. Disengage the two clips that secure the belt web guide (5) to the C-pillar. 9. Remove the screw (3) that secures the lower bracket of the retractor (4) to the C-pillar. 10. Disengage the hooks on the upper retractor bracket from the slots in the C-pillar above the retractor mounting hole. 11. Remove the rear outboard seat belt and retractor from the C-pillar as a unit. Front Center - Standard Cab FRONT CENTER - STANDARD CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: A front center seat belt and retractor is used only on standard cab vehicles. Quad cab and mega cab vehicles have a lap belt in the front center seating position. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 13968 1. Position the front center seat belt and retractor unit (5) to the floor panel (6) at the base of the cab back panel (8) to the right of center. 2. Install and tighten the two screws (4) that secure the front center seat belt retractor bracket to the floor panel near the base of the cab back panel. Tighten the screws to 40 Nm (29 ft. lbs.). 3. Position the belt bracket (2) of the front center seat belt (7) to the body bracket (1) on the upper cab back panel reinforcement. 4. Install and tighten the two screws (3) that secure the belt bracket of the front center seat belt to the body bracket on the upper cab back panel reinforcement. Tighten the screws to 20 Nm (15 ft. lbs.). 5. Reinstall the trim (1) onto the cab back panel. 6. Route the webbing of the front center seat belt (4) through the bezel (5) and position the bezel to the belt opening near the top of the cab back trim panel. 7. Using hand pressure, press firmly and evenly on each side of the front center seat belt bezel until it snaps into place on the cab back trim panel. 8. Reinstall the stowage tray onto the rear floor panel behind the seat. 9. Reach between the center of the front seat cushion and front seat back to access and buckle the front center seat belt lower anchor latch plate to the unique black, keyed lower anchor buckle. Front Outboard - Quad And Mega Cab FRONT OUTBOARD - QUAD AND MEGA CAB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 13969 WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. NOTE: The following procedure is for replacement of an ineffective or damaged seat belt and retractor unit. The front retractor also includes a seat belt tensioner. If the front seat belt or retractor is ineffective or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the unit from the vehicle. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. 1. Position the front outboard seat belt and retractor (7) to the inner B-pillar as a unit. Be certain to engage the tab on the upper retractor bracket into the hole in the B-pillar. 2. Loosely install the screw (6) that secures the lower retractor bracket to the B-pillar. 3. Install and tighten the screw (4) that secures the upper retractor bracket to the B-pillar. Tighten the screw to 12 Nm (105 in. lbs.). 4. Tighten the screw that secures the lower retractor bracket to the B-pillar. Tighten the screw to 39 Nm (29 ft. lbs.). 5. Position the belt web guide (1) to the B-pillar and use hand pressure to press it firmly and evenly until the two clips that secure it snap into place. 6. Reconnect the yellow body wire harness connector (5) to the seat belt tensioner initiator on the retractor. 7. Reinstall the lower trim (3) onto the inside of the B-pillar. Be certain that the turning loop (2) can be accessed from the face of the lower trim after the seat belt webbing is inserted through the slot in the trim. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 13970 8. Reinstall the upper trim (2) onto the inside of the B-pillar. 9. Position the seat belt turning loop (5) onto the height adjuster (1) on the upper B-pillar. 10. Install and tighten the screw (4) that secures the turning loop to the height adjuster. Tighten the screw to 39 Nm (29 ft. lbs.). 11. Engage the upper edge of a new trim cover (3) over the top of the turning loop. Then squeeze the lower end of the trim cover and the turning loop together firmly and evenly until the engagement tabs of the trim cover snap into the slots of the turning loop. 12. Position the seat belt (2) lower anchor to the mounting hole on the outboard side of the front seat (1) cushion frame. Be certain that the seat belt webbing between the turning loop and the lower anchor is not twisted. 13. Install and tighten the screw (3) that secures the lower anchor to the seat. Tighten the screw to 39 Nm (29 ft. lbs.). 14. Reinstall the lower anchor cover (4) onto the front seat cushion outboard side shield. 15. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Front Outboard - Standard Cab FRONT OUTBOARD - STANDARD CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 13971 retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. NOTE: The following procedure is for replacement of an ineffective or damaged seat belt and retractor unit. The front retractor also includes a seat belt tensioner. If the front seat belt or retractor is ineffective or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the unit from the vehicle. NOTE: The seat belt retractor on the driver side of all standard cab vehicles includes a tension reducer. All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. 1. Position the front outboard seat belt and retractor (7) to the inner B-pillar as a unit. Be certain to engage the tab on the upper retractor bracket into the hole in the B-pillar. 2. Loosely install the screw (6) that secures the lower retractor bracket to the B-pillar. 3. Install and tighten the screw (4) that secures the upper retractor bracket to the B-pillar. Tighten the screw to 12 Nm (105 in. lbs.). 4. Tighten the screw that secures the lower retractor bracket to the B-pillar. Tighten the screw to 39 Nm (29 ft. lbs.). 5. Position the belt web guide (1) to the B-pillar and use hand pressure to press it firmly and evenly until the two clips that secure it snap into place. 6. Reconnect the yellow body wire harness connector (5) to the seat belt tensioner initiator on the retractor. 7. On the driver side only, reconnect the white body wire harness connector to the seat belt tension reducer connector receptacle near the bottom of the retractor. 8. Reinstall the lower trim (3) onto the inside of the B-pillar. Be certain that the turning loop (2) can be accessed from the face of the lower trim after the seat belt webbing is inserted through the slot in the trim. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 13972 9. Reinstall the upper trim (2) onto the inside of the B-pillar 10. Position the seat belt turning loop (5) onto the height adjuster (1) on the upper B-pillar. 11. Install and tighten the screw (4) that secures the turning loop to the height adjuster. Tighten the screw to 39 Nm (29 ft. lbs.). 12. Engage the upper edge of a new trim cover (3) over the top of the turning loop. Then squeeze the lower end of the trim cover and the turning loop together firmly and evenly until the engagement tabs of the trim cover snap into the slots of the turning loop. 13. Position the seat belt (2) lower anchor to the mounting hole on the outboard side of the front seat (1) cushion frame. Be certain that the seat belt webbing between the turning loop and the lower anchor is not twisted. 14. Install and tighten the screw (3) that secures the lower anchor to the seat. Tighten the screw to 39 Nm (29 ft. lbs.). 15. Reinstall the lower anchor cover (4) onto the front seat cushion outboard side shield. 16. Reinstall the stowage tray onto the rear floor panel behind the seat. 17. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Rear Center - Mega Cab REAR CENTER - MEGA CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 13973 NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. 1. Position the rear center seat belt and retractor unit into the 60 percent section of the rear seat back frame (3). Be certain the tab (5) on the retractor bracket is engaged in the slot in the frame. 2. Install and tighten the screw (4) that secures the rear center seat belt retractor to the seat back frame. Tighten the screw to 60 Nm (44 ft. lbs.). 3. Position the belt bracket (1) of the rear center seat belt onto the top of the seat back frame. Be certain the tab (2) on the bracket is engaged in the slot in the frame. 4. Install and tighten the two screws (6) that secure the belt bracket of the rear center seat belt to the seat back frame. Tighten the screws to 60 Nm (44 ft. lbs.). 5. Reinstall the trim cover onto the 60 percent section of the rear seat back frame. 6. Engage the rear center seat belt bezel (2) over the webbing of the rear center seat belt. 7. Position the bezel over the belt bracket on the top of the rear seat back (1). 8. Install and tighten the two screws (3) that secure the bezel to the belt bracket on the top of the rear seat back frame. Tighten the screws to 5 Nm (44 in. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 13974 9. Route the center seat belt lower anchor between the seat back (1) and the seat cushion (2) and position it to the anchor bracket (3). Be certain the belt webbing is not twisted between the retractor and the anchor bracket. 10. Install and tighten the screw (7) that secures the seat belt lower anchor to the anchor bracket. Tighten the screw to 40 Nm (30 ft. lbs.). 11. Restore the 60 percent seat back filler panel and the seat back to their previous positions. Rear Center - Quad Cab REAR CENTER - QUAD CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: The rear center seat belt and retractor is secured to a mounting bracket that includes the right outboard occupant seat belt buckle. The rear right outboard occupant buckle is available for service only as a unit with the center seat belt and retractor. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. 1. Position the rear center seat belt retractor and right outboard occupant buckle unit (6) onto the rear floor panel near the base of the cab back panel (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 13975 2. Loosely install the screw (7) that secures the right side of the seat belt retractor mounting bracket and the right outboard occupant buckle unit to the rear floor panel near the base of the cab back panel. 3. Position the belt bracket of the rear center seat belt onto the body bracket on the upper cab back panel reinforcement. 4. Install and tighten the two screws (4) that secure the belt bracket to the body bracket. Tighten the screws to 20 Nm (15 ft. lbs.). 5. Lift the webbing of the rear center seat belt and slide the cover (3) over the belt bracket at the top of the cab back panel until it is fully seated. 6. Route the rear center seat belt bezel (2) over the webbing of the rear center seat belt. 7. Position the rear center seat belt bezel over the cover and belt bracket at the top of the cab back panel and engage the rearward snap features of the bezel with the belt bracket. Using hand pressure, press firmly and evenly downward on the front of the bezel until it snaps into place over the cover and belt bracket. 8. Reinstall the rear seat into the vehicle. On vehicles with the optional 60/40 split rear bench, only the 60 percent section (right side) of the rear seat must be reinstalled. 9. Insert the rear center seat belt lower anchor between the rear seat back and the seat cushion, and position the anchor to the left side of the seat belt retractor mounting bracket on the rear floor panel. 10. Install and tighten the screw (5) that secures the center seat belt lower anchor and the left side of the seat belt retractor mounting bracket to the rear floor panel. Tighten the screw to 40 Nm (29 ft. lbs.). 11. Tighten the screw that secures the right side of the seat belt retractor mounting bracket to the rear floor panel to 40 Nm (29 ft. lbs.). 12. Restore the rear seat cushion to its seating position. Rear Outboard - Mega Cab REAR OUTBOARD - MEGA CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. 1. Position the rear outboard seat belt and retractor (4) to the inner C-pillar as a unit. Be certain to engage the hooks on the upper retractor bracket into the mounting hole in the C-pillar. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 13976 2. Install and tighten the screw (3) that secures the lower retractor bracket to the C-pillar. Tighten the screw to 39 Nm (29 ft. lbs.). 3. Position the belt web guide (5) to the B-pillar and use hand pressure to press it firmly and evenly until the two clips that secure it snap into place. 4. Reinstall the lower trim (2) onto the inside of the C-pillar. Be certain that the turning loop (1) can be accessed from the face of the lower trim after the seat belt webbing is inserted through the slot in the trim. 5. Reinstall the upper trim (2) onto the inside of the C-pillar. 6. Position the seat belt turning loop (3) onto the height adjuster (1) on the upper C-pillar. 7. Install and tighten the screw (5) that secures the turning loop to the height adjuster. Tighten the screw to 39 Nm (29 ft. lbs.). 8. Engage the upper edge of a new trim cover (4) over the top of the turning loop. Then squeeze the lower end of the trim cover and the turning loop together firmly and evenly until the engagement tabs of the trim cover snap into the slots of the turning loop. 9. Position the seat belt lower anchor (7) to the mounting hole at the base of the C-pillar. 10. Install and tighten the screw (6) that secures the lower anchor to the C-pillar. Tighten the screw to 39 Nm (29 ft. lbs.). 11. Reinstall the rear seat into the vehicle. Rear Outboard - Quad Cab REAR OUTBOARD - QUAD CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 13977 1. Position the rear outboard seat belt and retractor (4) to the inner C-pillar as a unit. Be certain to engage the hooks on the upper retractor bracket into the mounting hole in the C-pillar. 2. Install and tighten the screw (3) that secures the lower retractor bracket to the C-pillar. Tighten the screw to 39 Nm (29 ft. lbs.). 3. Position the belt web guide (5) to the B-pillar and use hand pressure to press it firmly and evenly until the two clips that secure it snap into place. 4. Reinstall the lower trim (2) onto the inside of the C-pillar. Be certain that the turning loop (1) can be accessed from the face of the lower trim after the seat belt webbing is inserted through the slot in the trim. 5. Reinstall the upper trim (1) onto the inside of the C-pillar. 6. Position the seat belt turning loop (2) onto the upper C-pillar. 7. Install and tighten the screw (4) that secures the turning loop to the C-pillar. Tighten the screw to 39 Nm (29 ft. lbs.). 8. Engage the upper edge of a new trim cover (3) over the top of the turning loop. Then squeeze the lower end of the trim cover and the turning loop together firmly and evenly until the engagement tabs of the trim cover snap into the slots of the turning loop. 9. Position the seat belt lower anchor (6) to the mounting hole at the base of the C-pillar. 10. Install and tighten the screw (5) that secures the lower anchor to the C-pillar. Tighten the screw to 39 Nm (29 ft. lbs.). 11. Reinstall the rear seat into the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Removal Seat Belt Buckle: Service and Repair Removal Front Center And Center Anchor FRONT CENTER AND CENTER ANCHOR WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: A fixed position front center seat belt buckle is located on the left side of the front center seat section (20 percent) used on all vehicles. Standard cab vehicles have a unique, fixed position, black, keyed, lower anchor buckle for the three-point center seat belt lower anchor located on the right side of the front center seat section. Quad cab and mega cab vehicles have a fixed position front center seat lap belt located on the right side of the front center seat section. The following procedure applies to the front center seating position belt buckle, the lap belt or the anchor buckle. The three-point front center seat belt and retractor unit is only used on standard cab vehicles. 1. Move the adjacent right or left front outboard seat section (40 percent) to its most forward position and tilt the seat back forward for easiest access to the lower anchor of the front center seat belt buckle, lap belt or anchor buckle (1). 2. On standard cab vehicles only, remove the stowage tray from the rear floor panel behind the seat. 3. From behind the front seat, remove the screw (5) that secures the lower anchor of the front center seat belt buckle, lap belt or anchor buckle to the center seat support bracket (3). 4. From the front of the front seat, reach between the side of the center seat cushion (6) and the adjacent right or left front outboard seat cushion to access and remove the seat belt buckle, lap belt or anchor buckle through the elastic strap (2) on the side of the center seat cushion. 5. Remove the front center seat belt buckle, lap belt or anchor buckle unit from the front seat. Front Outboard FRONT OUTBOARD WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: A traveling front outboard seat belt buckle is located on the inboard side of each front outboard seat section (40 percent) used on all vehicles. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Removal > Page 13982 The seat belt buckle on the driver side front seat for all vehicles also includes a seat belt switch. 1. Move the right or left front outboard seat section to its most rearward position and tilt the seat back forward for easiest access to the front outboard seat belt buckle lower anchor. 2. On standard cab vehicles only, also move the outboard seat section opposite the side from which the buckle is to be removed to its most forward position and tilt the seat back forward. 3. On standard cab vehicles only, remove the stowage tray from the rear floor panel behind the seat. 4. For buckles equipped with a seat belt switch, from behind the front seat disconnect the seat belt switch pigtail wire connector (4) from the seat wire harness take out and connector located on the lower inboard side of the seat cushion frame just forward of the buckle lower anchor. 5. From behind the front seat, remove the screw (3) that secures the buckle (1) lower anchor to the lower inboard side of the seat cushion frame. 6. From the front of the front seat, reach between the center seat cushion (2) or center floor console and the right or left front outboard seat cushion to access and remove the front outboard seat belt buckle from the seat. Rear Center Anchor And Right Outboard - Mega Cab REAR CENTER ANCHOR AND RIGHT OUTBOARD - MEGA CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: The rear seat right outboard occupant buckle is serviced as a unit with an anchor bracket. The lower anchor of the rear center seat belt and retractor is also secured to the anchor bracket with a screw so that it can be removed from the anchor bracket and serviced separately from the buckle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Removal > Page 13983 1. Fold the 60 percent section of the rear seat back (2) down onto the seat cushion in the cargo storage position, then lift and prop open the seat back filler panel (3) as necessary for easiest access to the rear center seat belt lower anchor and right outboard buckle anchor bracket. 2. Remove the screw (7) that secures the center seat belt lower anchor to the anchor bracket (3) and temporarily secure the belt lower anchor to keep it from being pulled from between the seat back (1) and the seat cushion (2) by the retractor. 3. Remove and discard the screw (6) that secures the buckle anchor bracket and the rear seat rear mounting bracket (5) to the rear floor panel. 4. Remove the nut (4) that secures the buckle anchor bracket to the stud on the rear seat rear mounting bracket. 5. Disengage the buckle from between the seat cushion and the seat back, then remove the anchor bracket and buckle from behind the rear seat as a unit. Rear Center And Left Outboard - Mega Cab REAR CENTER AND LEFT OUTBOARD - MEGA CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Removal > Page 13984 1. Fold both the 40 percent section and the 60 percent section of the rear seat back (1 and 2) down onto the seat cushion in the cargo storage position, then lift and prop open the seat back filler panels (3 and 4) as necessary for easiest access to the rear center and left outboard seat belt buckle anchor bracket. 2. Remove the four screws (2) that secure the stabilizer bracket (4) to the two inboard seat hinge brackets. 3. Remove the stabilizer bracket from between the seat hinge brackets. 4. Remove and discard the screw (3) that secures the buckle anchor bracket (5) and the rear seat rear mounting bracket to the rear floor panel. 5. Remove the nut (1) that secures the buckle anchor bracket to the stud on the rear seat rear mounting bracket. 6. Disengage the buckles from between the seat cushion and the seat back, then remove the anchor bracket and buckles from between the rear seat sections as a unit. Rear - Quad Cab REAR - QUAD CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: The following removal procedure covers service of the rear seat center and left outboard seat belt buckle units. The rear seat right outboard seat belt buckle is serviced as a unit with the rear seat center seat belt and retractor assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Removal > Page 13985 1. Lift up the rear seat cushion into its stowed position against the rear seat back. 2. Remove the screw (2) that secures either the center (4) or the left outboard (3) occupant buckle unit to the rear floor panel near the base of the cab back panel (1). On vehicles with the optional 60/40 split rear bench, the screw that secures the buckle unit also secures one of the rear seat mounting brackets to the rear floor panel. 3. Remove the center or left outboard occupant buckle unit from the rear floor panel or from the rear seat mounting bracket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Removal > Page 13986 Seat Belt Buckle: Service and Repair Installation Front Center And Center Anchor FRONT CENTER AND CENTER ANCHOR WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: A fixed position front center seat belt buckle is located on the left side of the front center seat section (20 percent) used on all vehicles. Standard cab vehicles have a unique, fixed position, black, keyed, lower anchor buckle for the three-point center seat belt lower anchor located on the right side of the front center seat section. Quad cab and mega cab vehicles have a fixed position front center seat lap belt located on the right side of the front center seat section. The following procedure applies to the front center seating position belt buckle, the lap belt or the anchor buckle. The three-point front center seat belt and retractor unit is only used on standard cab vehicles. 1. From the front of the front seat, position the front center seat belt buckle, lap belt or anchor buckle unit (1) through the elastic strap (2) on the side of the center seat cushion (6). 2. From the front of the front seat, reach between the side of the center seat cushion and the adjacent right or left front outboard seat cushion to route the lower anchor of the seat belt buckle, lap belt or anchor buckle unit down between the side of the center seat cushion and the adjacent right or left front outboard seat cushion. Be certain that the belt webbing is not twisted. 3. From behind the front seat, position the lower anchor of the seat belt buckle, lap belt or anchor buckle to the center seat support bracket (3). Be certain to engage the anti-rotation tab on the lower anchor into the corresponding hole in the center seat support bracket. 4. Install and tighten the screw (5) that secures the lower anchor of the seat belt buckle, lap belt or anchor buckle to the center seat support bracket. Tighten the screw to 40 Nm (29 ft. lbs.). 5. On standard cab vehicles only, reinstall the stowage tray onto the rear floor panel behind the seat. Front Outboard FRONT OUTBOARD WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Removal > Page 13987 NOTE: A traveling front outboard seat belt buckle is located on the inboard side of each front outboard seat section (40 percent) used on all vehicles. The seat belt buckle on the driver side front seat for all vehicles also includes a seat belt switch. 1. From the front of the front seat, reach between the center seat cushion (2) or center floor console and the right or left front outboard seat cushion to position the front outboard seat belt buckle to the seat. 2. From behind the front seat, position the front outboard seat belt buckle lower anchor to the lower inboard side of the seat cushion frame. Be certain to engage the anti-rotation tab on the lower anchor into the corresponding hole in the seat cushion frame. 3. Install and tighten the screw (3) that secures the front outboard seat belt buckle lower anchor to the seat cushion frame. Tighten the screw to 25 Nm (18 ft. lbs.). 4. For buckles equipped with a seat belt switch, reconnect the seat belt switch pigtail wire connector (4) to the seat wire harness take out and connector located on the lower inboard side of the seat cushion frame just forward of the buckle lower anchor. 5. On standard cab vehicles only, reinstall the stowage tray onto the rear floor panel behind the seat. Rear Center Anchor And Right Outboard - Mega Cab REAR CENTER ANCHOR AND RIGHT OUTBOARD - MEGA CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: The rear seat right outboard occupant buckle is serviced as a unit with a mounting bracket. The lower anchor of the rear center seat belt and retractor is also secured to the mounting bracket with a screw so that it can be removed from the mounting bracket and serviced separately from the buckle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Removal > Page 13988 1. Engage the buckle unit between the seat cushion (2) and the seat back (1), then position the anchor bracket (3) to the rear seat rear mounting bracket (5) behind the rear seat as a unit. Be certain to engage the anti-rotation tab on the anchor bracket into the clearance hole in the mounting bracket. 2. Install and tighten the nut (4) that secures the buckle anchor bracket to the stud on the rear seat rear mounting bracket. Tighten the nut to 23 Nm (17 ft. lbs.). 3. Install and tighten a new screw (6) to secure the buckle anchor bracket and the rear seat rear mounting bracket to the rear floor panel. Tighten the screw to 47 Nm (35 ft. lbs.). 4. Route the center seat belt lower anchor between the seat back and the seat cushion and position it to the anchor bracket. Be certain the belt webbing is not twisted between the retractor and the anchor bracket. 5. Install and tighten the screw (7) that secures the seat belt lower anchor to the anchor bracket. Tighten the screw to 40 Nm (30 ft. lbs.). 6. Restore the 60 percent seat back filler panel and the seat back to their previous positions. Rear Center And Left Outboard - Mega Cab REAR CENTER AND LEFT OUTBOARD - MEGA CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. 1. Position the buckles and anchor bracket (5) between the inboard rear seat hinge brackets and engage the buckle units between the seat cushion and the seat back as a unit. Be certain to engage the anti-rotation tab on the anchor bracket into the clearance hole in the rear seat rear mounting bracket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Removal > Page 13989 2. Install and tighten the nut (1) that secures the buckle anchor bracket to the stud on the rear seat rear mounting bracket. Tighten the nut to 23 Nm (17 ft. lbs.). 3. Install and tighten a new screw (3) to secure the buckle anchor bracket and the rear seat rear mounting bracket to the rear floor panel. Tighten the screw to 47 Nm (35 ft. lbs.). 4. Position the stabilizer bracket (4) between the two inboard rear seat hinge brackets. 5. Install and tighten the four screws (2) that secure the stabilizer bracket to the hinge brackets. Tighten the screws to 5 Nm (44 in. lbs.). 6. Restore both seat back filler panels and both seat backs to their previous positions. Rear - Quad Cab REAR - QUAD CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: The following installation procedure covers service of the rear seat center and left outboard seat belt buckle units. The rear seat right outboard seat belt buckle is serviced as a unit with the rear seat center seat belt and retractor assembly. 1. Position the center (4) or the left outboard (3) occupant buckle unit onto the rear floor panel or onto the rear seat mounting bracket near the base of the cab back panel (1). On vehicles with the optional 60/40 split rear bench, the screw that secures the buckle unit also secures one of the rear seat mounting brackets to the rear floor panel. 2. Install and tighten the screw (2) that secures the center or the left outboard occupant buckle unit to the rear floor panel. Tighten the screw to 40 Nm (29 ft. lbs.). 3. Restore the rear seat cushion to its seating position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Component ID: 483 Component : SWITCH-SEAT BELT-DRIVER Connector: Name : SWITCH-SEAT BELT-DRIVER Color : # of pins : 2 Qualifier : (HD) Pin Description Circuit 1 GROUND Z951 18BK 2 SEAT BELT SWITCH SENSE G10 20VT/LG Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 13993 Connector: Name : SWITCH-SEAT BELT-DRIVER Color : LT. GRAY # of pins : 2 Qualifier : (LD) Pin Description Circuit 1 GROUND Z917 20BK 2 DRIVER SEAT BELT SWITCH SENSE R57 20LG/GY Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 13994 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 13995 Seat Belt Buckle Switch: Diagrams Component ID: 483 Component : SWITCH-SEAT BELT-DRIVER Connector: Name : SWITCH-SEAT BELT-DRIVER Color : # of pins : 2 Qualifier : (HD) Pin Description Circuit 1 GROUND Z951 18BK 2 SEAT BELT SWITCH SENSE G10 20VT/LG Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 13996 Connector: Name : SWITCH-SEAT BELT-DRIVER Color : LT. GRAY # of pins : 2 Qualifier : (LD) Pin Description Circuit 1 GROUND Z917 20BK 2 DRIVER SEAT BELT SWITCH SENSE R57 20LG/GY Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 13997 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Description Seat Belt Buckle Switch: Description and Operation Description DESCRIPTION All vehicles are equipped with a driver side seat belt switch that is a small, normally open, single pole, single throw, leaf contact, momentary switch. The driver side seat belt switch is integral to the buckle (1) of the driver side front seat belt buckle, which is located on a stamped steel stanchion secured by a screw (3) to the inboard side of the driver side front seat cushion frame. The seat belt switch is connected to the vehicle electrical system through a two-lead pigtail wire and connector (4) on the seat belt buckle-half, which is connected to a wire harness connector and take out of the seat wire harness routed beneath the driver side front seat cushion in the passenger compartment. The seat belt switch cannot be adjusted or repaired. If ineffective or damaged, the entire driver side front seat belt buckle-half unit must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Description > Page 14000 Seat Belt Buckle Switch: Description and Operation Operation OPERATION The driver side seat belt switch is designed to control a path to ground for the seat belt switch sense input of the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). When the driver side front seat belt tip-half is inserted into the seat belt buckle, the switch closes the path to ground; and, when the driver side front seat belt tip-half is removed from the seat belt buckle, the switch opens the ground path. The switch is actuated by the latch mechanism within the seat belt buckle. The seat belt switch is connected in series between ground and the seat belt switch sense input of the instrument cluster. The seat belt switch receives ground at all times through its pigtail wire connection to the seat wire harness from a take out of the body wire harness. An eyelet terminal connector on the body wire harness ground take out is secured beneath a ground screw on the left cowl side inner panel, beneath the instrument panel. The seat belt switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal Seat Belt Height Adjuster: Service and Repair Removal Front FRONT WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. 1. Unsnap the trim cover from the front seat belt turning loop and discard. 2. Remove the screw that secures the seat belt turning loop to the height adjuster (2) on the inside of the upper B-pillar (1). 3. Remove the seat belt turning loop from the height adjuster. 4. Remove the upper trim from the inside of the B-pillar. 5. Loosen the two screws (3) that secure the height adjuster far enough to remove the adjuster from the upper B-pillar. 6. Disengage the tab near the lower end of the height adjuster from the slot in the sheet metal and remove the adjuster from the inside of the B-pillar. Rear - Mega Cab REAR - MEGA CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal > Page 14005 1. Unsnap the trim cover (4) from the front seat belt turning loop (3) and discard. 2. Remove the screw (5) that secures the seat belt turning loop to the height adjuster (1) on the upper C-pillar. 3. Remove the seat belt turning loop from the height adjuster. 4. Remove the upper trim (2) from the inside of the C-pillar. 5. Loosen the two screws that secure the height adjuster far enough to remove the adjuster from the upper C-pillar. 6. Disengage the tab of the height adjuster from the slot in the sheet metal and remove the adjuster from the inside of the C-pillar. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal > Page 14006 Seat Belt Height Adjuster: Service and Repair Installation Front FRONT WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. 1. Position the front seat belt turning loop height adjuster (2) to the inside of the B-pillar (1). 2. Engage the tab near the lower end of the height adjuster into the slot in the sheet metal of the inner B-pillar. 3. Hand tighten the lower of the two screws (3) that secure the height adjuster to the B-pillar far enough to keep the tab on the lower end of the adjuster engaged in the B-pillar slot. 4. Install the upper screw that secures the seat belt turning loop height adjuster to the upper B-pillar, then tighten both the upper and lower screws to 39 Nm (29 ft. lbs.). 5. Reinstall the upper trim onto the inside of the B-pillar. 6. Position the seat belt turning loop onto the height adjuster on the upper B-pillar. 7. Install and tighten the screw that secures the turning loop to the height adjuster. Tighten the screw to 39 Nm (29 ft. lbs.). 8. Engage the upper edge of a new trim cover over the top of the turning loop. Then squeeze the lower end of the trim cover and the turning loop together firmly and evenly until the engagement tabs of the trim cover snap into the slots of the turning loop. Rear - Mega Cab REAR - MEGA CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal > Page 14007 1. Position the rear seat belt turning loop height adjuster (1) to the inside of the upper C-pillar. 2. Engage the tab on the height adjuster into the slot in the sheet metal of the inner C-pillar. 3. Hand tighten the lower of the two screws that secure the height adjuster to the C-pillar far enough to keep the tab on the adjuster engaged in the C-pillar slot. 4. Install the upper screw that secures the seat belt turning loop height adjuster to the upper C-pillar, then tighten both the upper and lower screws to 39 Nm (29 ft. lbs.). 5. Reinstall the upper trim (2) onto the inside of the C-pillar. 6. Position the seat belt turning loop (3) onto the height adjuster on the upper C-pillar. 7. Install and tighten the screw (5) that secures the turning loop to the height adjuster. Tighten the screw to 39 Nm (29 ft. lbs.). 8. Engage the upper edge of a new trim cover (4) over the top of the turning loop. Then squeeze the lower end of the trim cover and the turning loop together firmly and evenly until the engagement tabs of the trim cover snap into the slots of the turning loop. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation > Description Seat Belt Reminder Lamp: Description and Operation Description DESCRIPTION A seatbelt indicator is standard equipment on all instrument clusters. The seatbelt indicator is located near the upper edge of the instrument cluster, between the tachometer and the speedometer. The seatbelt indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Seat Belt in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The seatbelt indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation > Description > Page 14012 Seat Belt Reminder Lamp: Description and Operation Operation OPERATION The seatbelt indicator gives an indication to the vehicle operator of the status of the driver side front seatbelt. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and a hard wired input from the seatbelt switch in the driver side front seatbelt buckle through the seat belt indicator driver circuit. The seatbelt indicator also includes a programmable enhanced seatbelt reminder or BELTMINDER feature that is enabled when the vehicle is shipped from the factory. This BELTMINDER feature can be disabled and enabled by the customer using a specific programming event sequence, or by the dealer using a diagnostic scan tool. The seatbelt indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the seatbelt indicator for the following reasons: - Seatbelt Reminder Function - Each time the cluster receives a battery current input on the fused ignition switch output (run-start) circuit, the indicator will be illuminated as a seatbelt reminder for about six seconds, or until the ignition switch is turned to the OFF position, whichever occurs first. This reminder function will occur regardless of the status of the seatbelt switch input to the cluster. - Driver Side Front Seatbelt Not Buckled - Beltminder Active - Following the seatbelt reminder function, each time the cluster detects an open circuit on the seat belt indicator driver circuit (seatbelt switch open = seatbelt unbuckled) with the ignition switch in the START or ON positions, the indicator will be illuminated. In addition, if the driver side front seat belt remains unbuckled about 60 seconds after the conclusion of the seatbelt reminder function with the vehicle speed greater than about 8 kilometers-per-hour (5 miles-per-hour), the seatbelt indicator will begin to cycle between flashing ON and OFF for 3 seconds, then lighting solid for 2 seconds. The seatbelt indicator will continue to cycle between flashing and solid illumination for 13 complete cycles, until the seat belt indicator driver input to the cluster is closed to ground (seatbelt switch closed = seatbelt buckled), or until the ignition switch is turned to the OFF position, whichever occurs first. - Driver Side Front Seatbelt Not Buckled - Beltminder Inactive - Following the seatbelt reminder function, each time the cluster detects an open circuit on the seat belt indicator driver circuit (seatbelt switch open = seatbelt unbuckled) with the ignition switch in the START or ON positions, the indicator will be illuminated. The seatbelt indicator remains illuminated until the seat belt indicator driver input to the cluster is closed to ground (seatbelt switch closed = seatbelt buckled), or until the ignition switch is turned to the OFF position, whichever occurs first. - Airbag Indicator Backup - If the instrument cluster detects a fault in the airbag indicator circuit it will send an electronic message indicating the fault to the Occupant Restraint Controller (ORC), then flash the seatbelt indicator ON and OFF. The cluster will continue to flash the indicator until the airbag indicator circuit fault is resolved, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the seatbelt indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The seatbelt switch is connected in series between ground and the seat belt indicator driver input to the instrument cluster. The hard wired seatbelt switch input to the instrument cluster may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Description and Operation > Description Seat Belt Retractor: Description and Operation Description DESCRIPTION The seat belt retractors used in all seating positions include an inertia-type, emergency locking mechanism (7) as standard equipment. However, the retractor locking mechanisms for all seating positions except the driver side front position are mechanically switchable from an emergency locking retractor to an automatic locking retractor. The primary function of this feature is to securely accommodate a child seat in any seating position of the vehicle without the need for a self-cinching seat belt tip half latch plate unit or another supplemental device that would be required to prevent the seat belt webbing from unwinding freely from the retractor spool of an inertia-type emergency locking retractor mechanism. The automatic locking mechanism is integral to the seat belt and retractor unit and is concealed beneath a molded plastic cover located on one side of the retractor spool. The automatic locking mechanism cannot be adjusted or repaired and, if ineffective or damaged, the entire passenger side front seat belt and retractor unit must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Description and Operation > Description > Page 14017 Seat Belt Retractor: Description and Operation Operation OPERATION The locked mode of the automatic locking retractor is engaged and the retractor is switched from operating as a standard inertia-type emergency locking retractor by first buckling the combination lap and shoulder belt buckle. Then grasp the shoulder belt and pull all of the webbing out of the retractor. Once all of the belt webbing is extracted from the spool, the retractor will automatically become engaged in the pre-locked automatic locking mode and will make a light, audible clicking or ratcheting sound as the shoulder belt is allowed to retract to confirm that the automatic locking mode is now engaged. Once the automatic locking mode is engaged, the retractor will remain locked and the belt will remain tight around whatever it is restraining. The retractor is returned to standard emergency locking (inertia) mode by unbuckling the combination lap and shoulder belt buckle and allowing the belt webbing to be almost fully retracted onto the retractor spool. The emergency locking mode is confirmed by the absence of the light, audible clicking or ratcheting sound as the belt webbing retracts. This mode will allow the belt to unwind from and wind onto the retractor spool freely unless and until a predetermined inertia load is sensed, or until the retractor is again switched to the automatic locking mode. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Removal Seat Belt Retractor: Service and Repair Removal Front Center - Standard Cab FRONT CENTER - STANDARD CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: A front center seat belt and retractor is used only on standard cab vehicles. Quad cab and mega cab vehicles have a lap belt in the front center seating position. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. 1. Reach between the center of the front seat cushion and front seat back to access and unbuckle the front center seat belt lower anchor latch plate from the unique black, keyed lower anchor buckle. Use an ignition key or a small screwdriver to depress the small white release button on the anchor buckle. 2. Move the front seat to its most forward position for easiest access to the front center seat belt and retractor unit. 3. Remove the stowage tray from the rear floor panel behind the seat. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry at each side of the front center seat belt bezel (5) on the cab back trim panel (1) to release the snap features that secure the bezel to the panel. 5. Remove the bezel from the webbing of the front center seat belt (4). 6. Remove the trim from the cab back panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Removal > Page 14020 7. Remove the two screws (3) that secure the belt bracket (2) of the front center seat belt (7) to the body bracket (1) on the upper cab back panel (8) reinforcement. 8. Remove the belt bracket of the front center seat belt from the body bracket on the upper cab back panel reinforcement. 9. Remove the two screws (4) that secure the front center seat belt retractor bracket (5) to the floor panel (6) near the base of the cab back panel. 10. Remove the front center seat belt and retractor unit from the floor panel. Front Outboard - Quad And Mega Cab FRONT OUTBOARD - QUAD AND MEGA CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. NOTE: The following procedure is for replacement of an ineffective or damaged seat belt and retractor unit. The front retractor also includes a seat belt tensioner. If the front seat belt or retractor is ineffective or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the unit from the vehicle. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Removal > Page 14021 1. Adjust the front seat to its most forward position for easiest access to the front seat belt (2) lower anchor cover (4) and the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Grasp the upper edge of the lower anchor cover and pull upward to unsnap it from the front seat cushion outboard side shield. 4. Remove the screw (3) that secures the lower anchor to the outboard side of the front seat cushion frame. 5. Unsnap the trim cover (3) from the front seat belt turning loop (5) and discard. 6. Remove the screw (4) that secures the seat belt turning loop to the height adjuster (1) on the upper B-pillar. 7. Remove the seat belt turning loop from the height adjuster. 8. Remove the upper trim (2) from the inside of the B-pillar. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Removal > Page 14022 9. Remove the lower trim (3) from the inside of the B-pillar.. 10. Disconnect the yellow body wire harness connector (5) from the seat belt tensioner initiator on the retractor (7). 11. Disengage the two clips that secure the belt web guide (1) to the B-pillar. 12. Remove the screw (4) that secures the upper retractor bracket to the B-pillar. 13. Remove the screw (6) that secures the lower retractor bracket to the B-pillar. 14. Disengage the locating tab on the upper retractor bracket from the hole in the inner B-pillar. 15. Remove the front outboard seat belt and retractor from the B-pillar as a unit. Front Outboard - Standard Cab FRONT OUTBOARD - STANDARD CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. NOTE: The following procedure is for replacement of an ineffective or damaged seat belt and retractor unit. The front retractor also includes a seat belt tensioner. If the front seat belt or retractor is ineffective or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the unit from the vehicle. NOTE: The seat belt retractor on the driver side of all standard cab vehicles includes a tension reducer. All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Removal > Page 14023 1. Adjust the front seat (1) to its most forward position for easiest access to the front seat belt (2) lower anchor cover (4) and the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the stowage tray from the rear floor panel behind the seat. 4. Grasp the upper edge of the lower anchor cover and pull upward to unsnap it from the front seat cushion outboard side shield. 5. Remove the screw (3) that secures the lower anchor to the outboard side of the front seat cushion frame. 6. Unsnap the trim cover (3) from the front seat belt turning loop (5) and discard. 7. Remove the screw (4) that secures the seat belt turning loop to the height adjuster (1) on the upper B-pillar. 8. Remove the seat belt turning loop from the height adjuster. 9. Remove the upper trim (2) from the inside of the B-pillar. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Removal > Page 14024 10. Remove the lower trim (3) from the inside of the B-pillar. 11. Disconnect the yellow body wire harness connector (5) from the seat belt tensioner initiator on the retractor (7). 12. On the driver side only, disconnect the white body wire harness connector from the connector receptacle for the seat belt tension reducer located near the bottom of the retractor. 13. Disengage the two clips that secure the belt web guide (1) to the B-pillar. 14. Remove the screw (4) that secures the upper retractor bracket to the B-pillar. 15. Remove the screw (6) that secures the lower retractor bracket to the B-pillar. 16. Disengage the locating tab on the upper retractor bracket from the hole in the inner B-pillar. 17. Remove the front outboard seat belt and retractor from the B-pillar as a unit. Rear Center - Mega Cab REAR CENTER - MEGA CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. 1. Fold the 60 percent section of the rear seat back (2) down onto the seat cushion in the cargo storage position, then lift and prop open the seat back Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Removal > Page 14025 filler panel (3) as necessary for easiest access to the rear center seat belt lower anchor and right outboard buckle anchor bracket. 2. Remove the screw (7) that secures the center seat belt lower anchor to the anchor bracket (3) and, from the front of the seat back, pull the belt lower anchor out from between the seat back (1) and the seat cushion (2). 3. Remove the two screws (3) that secure the bezel (2) to the top of the 60 percent section of the rear seat back (1). 4. Remove the bezel from the webbing of the rear center seat belt. 5. Remove the trim cover from the 60 percent section of the rear seat back. 6. Remove the two screws (6) that secure the belt bracket (1) of the rear center seat belt to the top of the seat back frame (3). 7. Disengage the belt bracket of the rear center seat belt from the seat back frame. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Removal > Page 14026 8. Remove the screw (4) that secures the rear center seat belt retractor to the seat back frame. 9. Remove the seat belt and retractor from the rear seat back as a unit. Rear Center - Quad Cab REAR CENTER - QUAD CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: The rear center seat belt and retractor is secured to a mounting bracket that includes the right outboard occupant seat belt buckle. The rear right outboard occupant buckle is available for service only as a unit with the center seat belt and retractor. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. 1. Lift up the rear seat cushion into its stowed position against the rear seat back. 2. Remove the screw (5) that secures the center seat belt lower anchor and the left side of the seat belt retractor mounting bracket to the rear floor panel. 3. Remove the rear seat from the vehicle. On vehicles with the optional 60/40 split rear bench, only the 60 percent section (right side) of the rear seat must be removed. 4. Lift upward on the forward edge of the rear center seat belt bezel (2) at the top of the cab back panel (1) to release the snap features that secure the bezel to the belt bracket. 5. Remove the bezel from the webbing of the rear center seat belt. 6. Lift the rear center seat belt cover (3) off of the belt bracket at the top of the cab back panel and remove the cover from the webbing of the rear center seat belt. 7. Remove the two screws (4) that secure the belt bracket of the rear center seat belt to the body bracket on the upper cab back panel reinforcement. 8. Remove the belt bracket of the rear center seat belt from the body bracket. 9. Remove the screw (7) that secures the right side of the seat belt retractor mounting bracket and the right outboard occupant buckle (6) unit to the rear floor panel near the base of the cab back panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Removal > Page 14027 10. Remove the rear center seat belt and retractor unit from the vehicle. Rear Outboard - Mega Cab REAR OUTBOARD - MEGA CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. 1. Remove the rear seat from the vehicle. 2. Remove the screw (6) that secures the seat belt lower anchor (7) to the base of the inner C-pillar. 3. Unsnap the trim cover (4) from the front seat belt turning loop (3) and discard. 4. Remove the screw (5) that secures the seat belt turning loop to the height adjuster (1) on the upper C-pillar. 5. Remove the seat belt turning loop from the height adjuster. 6. Remove the upper trim (2) from the inside of the C-pillar. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Removal > Page 14028 7. Remove the lower trim (2) from the inside of the C-pillar. 8. Disengage the two clips that secure the belt web guide (5) to the C-pillar. 9. Remove the screw (3) that secures the lower bracket of the retractor (4) to the C-pillar. 10. Disengage the hooks on the upper retractor bracket from the slots in the C-pillar above the retractor mounting hole. 11. Remove the rear outboard seat belt and retractor from the C-pillar as a unit. Rear Outboard - Quad Cab REAR OUTBOARD - QUAD CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. 1. Remove the rear seat from the vehicle. 2. Remove the screw (5) that secures the seat belt lower anchor (6) to the base of the inner C-pillar. 3. Unsnap the trim cover (3) from the front seat belt turning loop (2) and discard. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Removal > Page 14029 4. Remove the screw (4) that secures the seat belt turning loop to the upper C-pillar. 5. Remove the seat belt turning loop from the upper C-pillar. 6. Remove the upper trim (1) from the inside of the C-pillar. 7. Remove the lower trim (2) from the inside of the C-pillar. 8. Disengage the two clips that secure the belt web guide (5) to the C-pillar. 9. Remove the screw (3) that secures the lower bracket of the retractor (4) to the C-pillar. 10. Disengage the hooks on the upper retractor bracket from the slots in the C-pillar above the retractor mounting hole. 11. Remove the rear outboard seat belt and retractor from the C-pillar as a unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Removal > Page 14030 Seat Belt Retractor: Service and Repair Installation Front Center - Standard Cab FRONT CENTER - STANDARD CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: A front center seat belt and retractor is used only on standard cab vehicles. Quad cab and mega cab vehicles have a lap belt in the front center seating position. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. 1. Position the front center seat belt and retractor unit (5) to the floor panel (6) at the base of the cab back panel (8) to the right of center. 2. Install and tighten the two screws (4) that secure the front center seat belt retractor bracket to the floor panel near the base of the cab back panel. Tighten the screws to 40 Nm (29 ft. lbs.). 3. Position the belt bracket (2) of the front center seat belt (7) to the body bracket (1) on the upper cab back panel reinforcement. 4. Install and tighten the two screws (3) that secure the belt bracket of the front center seat belt to the body bracket on the upper cab back panel reinforcement. Tighten the screws to 20 Nm (15 ft. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Removal > Page 14031 5. Reinstall the trim (1) onto the cab back panel. 6. Route the webbing of the front center seat belt (4) through the bezel (5) and position the bezel to the belt opening near the top of the cab back trim panel. 7. Using hand pressure, press firmly and evenly on each side of the front center seat belt bezel until it snaps into place on the cab back trim panel. 8. Reinstall the stowage tray onto the rear floor panel behind the seat. 9. Reach between the center of the front seat cushion and front seat back to access and buckle the front center seat belt lower anchor latch plate to the unique black, keyed lower anchor buckle. Front Outboard - Quad And Mega Cab FRONT OUTBOARD - QUAD AND MEGA CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. NOTE: The following procedure is for replacement of an ineffective or damaged seat belt and retractor unit. The front retractor also includes a seat belt tensioner. If the front seat belt or retractor is ineffective or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the unit from the vehicle. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Removal > Page 14032 1. Position the front outboard seat belt and retractor (7) to the inner B-pillar as a unit. Be certain to engage the tab on the upper retractor bracket into the hole in the B-pillar. 2. Loosely install the screw (6) that secures the lower retractor bracket to the B-pillar. 3. Install and tighten the screw (4) that secures the upper retractor bracket to the B-pillar. Tighten the screw to 12 Nm (105 in. lbs.). 4. Tighten the screw that secures the lower retractor bracket to the B-pillar. Tighten the screw to 39 Nm (29 ft. lbs.). 5. Position the belt web guide (1) to the B-pillar and use hand pressure to press it firmly and evenly until the two clips that secure it snap into place. 6. Reconnect the yellow body wire harness connector (5) to the seat belt tensioner initiator on the retractor. 7. Reinstall the lower trim (3) onto the inside of the B-pillar. Be certain that the turning loop (2) can be accessed from the face of the lower trim after the seat belt webbing is inserted through the slot in the trim. 8. Reinstall the upper trim (2) onto the inside of the B-pillar. 9. Position the seat belt turning loop (5) onto the height adjuster (1) on the upper B-pillar. 10. Install and tighten the screw (4) that secures the turning loop to the height adjuster. Tighten the screw to 39 Nm (29 ft. lbs.). 11. Engage the upper edge of a new trim cover (3) over the top of the turning loop. Then squeeze the lower end of the trim cover and the turning loop together firmly and evenly until the engagement tabs of the trim cover snap into the slots of the turning loop. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Removal > Page 14033 12. Position the seat belt (2) lower anchor to the mounting hole on the outboard side of the front seat (1) cushion frame. Be certain that the seat belt webbing between the turning loop and the lower anchor is not twisted. 13. Install and tighten the screw (3) that secures the lower anchor to the seat. Tighten the screw to 39 Nm (29 ft. lbs.). 14. Reinstall the lower anchor cover (4) onto the front seat cushion outboard side shield. 15. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Front Outboard - Standard Cab FRONT OUTBOARD - STANDARD CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. NOTE: The following procedure is for replacement of an ineffective or damaged seat belt and retractor unit. The front retractor also includes a seat belt tensioner. If the front seat belt or retractor is ineffective or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the unit from the vehicle. NOTE: The seat belt retractor on the driver side of all standard cab vehicles includes a tension reducer. All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Removal > Page 14034 1. Position the front outboard seat belt and retractor (7) to the inner B-pillar as a unit. Be certain to engage the tab on the upper retractor bracket into the hole in the B-pillar. 2. Loosely install the screw (6) that secures the lower retractor bracket to the B-pillar. 3. Install and tighten the screw (4) that secures the upper retractor bracket to the B-pillar. Tighten the screw to 12 Nm (105 in. lbs.). 4. Tighten the screw that secures the lower retractor bracket to the B-pillar. Tighten the screw to 39 Nm (29 ft. lbs.). 5. Position the belt web guide (1) to the B-pillar and use hand pressure to press it firmly and evenly until the two clips that secure it snap into place. 6. Reconnect the yellow body wire harness connector (5) to the seat belt tensioner initiator on the retractor. 7. On the driver side only, reconnect the white body wire harness connector to the seat belt tension reducer connector receptacle near the bottom of the retractor. 8. Reinstall the lower trim (3) onto the inside of the B-pillar. Be certain that the turning loop (2) can be accessed from the face of the lower trim after the seat belt webbing is inserted through the slot in the trim. 9. Reinstall the upper trim (2) onto the inside of the B-pillar. 10. Position the seat belt turning loop (5) onto the height adjuster (1) on the upper B-pillar. 11. Install and tighten the screw (4) that secures the turning loop to the height adjuster. Tighten the screw to 39 Nm (29 ft. lbs.). 12. Engage the upper edge of a new trim cover (3) over the top of the turning loop. Then squeeze the lower end of the trim cover and the turning loop together firmly and evenly until the engagement tabs of the trim cover snap into the slots of the turning loop. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Removal > Page 14035 13. Position the seat belt (2) lower anchor to the mounting hole on the outboard side of the front seat (1) cushion frame. Be certain that the seat belt webbing between the turning loop and the lower anchor is not twisted. 14. Install and tighten the screw (3) that secures the lower anchor to the seat. Tighten the screw to 39 Nm (29 ft. lbs.). 15. Reinstall the lower anchor cover (4) onto the front seat cushion outboard side shield. 16. Reinstall the stowage tray onto the rear floor panel behind the seat. 17. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Rear Center - Mega Cab REAR CENTER - MEGA CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. 1. Position the rear center seat belt and retractor unit into the 60 percent section of the rear seat back frame (3). Be certain the tab (5) on the retractor bracket is engaged in the slot in the frame. 2. Install and tighten the screw (4) that secures the rear center seat belt retractor to the seat back frame. Tighten the screw to 60 Nm (44 ft. lbs.). 3. Position the belt bracket (1) of the rear center seat belt onto the top of the seat back frame. Be certain the tab (2) on the bracket is engaged in the Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Removal > Page 14036 slot in the frame. 4. Install and tighten the two screws (6) that secure the belt bracket of the rear center seat belt to the seat back frame. Tighten the screws to 60 Nm (44 ft. lbs.). 5. Reinstall the trim cover onto the 60 percent section of the rear seat back frame. 6. Engage the rear center seat belt bezel (2) over the webbing of the rear center seat belt. 7. Position the bezel over the belt bracket on the top of the rear seat back (1). 8. Install and tighten the two screws (3) that secure the bezel to the belt bracket on the top of the rear seat back frame. Tighten the screws to 5 Nm (44 in. lbs.). 9. Route the center seat belt lower anchor between the seat back (1) and the seat cushion (2) and position it to the anchor bracket (3). Be certain the belt webbing is not twisted between the retractor and the anchor bracket. 10. Install and tighten the screw (7) that secures the seat belt lower anchor to the anchor bracket. Tighten the screw to 40 Nm (30 ft. lbs.). 11. Restore the 60 percent seat back filler panel and the seat back to their previous positions. Rear Center - Quad Cab REAR CENTER - QUAD CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Removal > Page 14037 NOTE: The rear center seat belt and retractor is secured to a mounting bracket that includes the right outboard occupant seat belt buckle. The rear right outboard occupant buckle is available for service only as a unit with the center seat belt and retractor. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. 1. Position the rear center seat belt retractor and right outboard occupant buckle unit (6) onto the rear floor panel near the base of the cab back panel (1). 2. Loosely install the screw (7) that secures the right side of the seat belt retractor mounting bracket and the right outboard occupant buckle unit to the rear floor panel near the base of the cab back panel. 3. Position the belt bracket of the rear center seat belt onto the body bracket on the upper cab back panel reinforcement. 4. Install and tighten the two screws (4) that secure the belt bracket to the body bracket. Tighten the screws to 20 Nm (15 ft. lbs.). 5. Lift the webbing of the rear center seat belt and slide the cover (3) over the belt bracket at the top of the cab back panel until it is fully seated. 6. Route the rear center seat belt bezel (2) over the webbing of the rear center seat belt. 7. Position the rear center seat belt bezel over the cover and belt bracket at the top of the cab back panel and engage the rearward snap features of the bezel with the belt bracket. Using hand pressure, press firmly and evenly downward on the front of the bezel until it snaps into place over the cover and belt bracket. 8. Reinstall the rear seat into the vehicle. On vehicles with the optional 60/40 split rear bench, only the 60 percent section (right side) of the rear seat must be reinstalled. 9. Insert the rear center seat belt lower anchor between the rear seat back and the seat cushion, and position the anchor to the left side of the seat belt retractor mounting bracket on the rear floor panel. 10. Install and tighten the screw (5) that secures the center seat belt lower anchor and the left side of the seat belt retractor mounting bracket to the rear floor panel. Tighten the screw to 40 Nm (29 ft. lbs.). 11. Tighten the screw that secures the right side of the seat belt retractor mounting bracket to the rear floor panel to 40 Nm (29 ft. lbs.). 12. Restore the rear seat cushion to its seating position. Rear Outboard - Mega Cab REAR OUTBOARD - MEGA CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Removal > Page 14038 retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. 1. Position the rear outboard seat belt and retractor (4) to the inner C-pillar as a unit. Be certain to engage the hooks on the upper retractor bracket into the mounting hole in the C-pillar. 2. Install and tighten the screw (3) that secures the lower retractor bracket to the C-pillar. Tighten the screw to 39 Nm (29 ft. lbs.). 3. Position the belt web guide (5) to the B-pillar and use hand pressure to press it firmly and evenly until the two clips that secure it snap into place. 4. Reinstall the lower trim (2) onto the inside of the C-pillar. Be certain that the turning loop (1) can be accessed from the face of the lower trim after the seat belt webbing is inserted through the slot in the trim. 5. Reinstall the upper trim (2) onto the inside of the C-pillar. 6. Position the seat belt turning loop (3) onto the height adjuster (1) on the upper C-pillar. 7. Install and tighten the screw (5) that secures the turning loop to the height adjuster. Tighten the screw to 39 Nm (29 ft. lbs.). 8. Engage the upper edge of a new trim cover (4) over the top of the turning loop. Then squeeze the lower end of the trim cover and the turning loop together firmly and evenly until the engagement tabs of the trim cover snap into the slots of the turning loop. 9. Position the seat belt lower anchor (7) to the mounting hole at the base of the C-pillar. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Removal > Page 14039 10. Install and tighten the screw (6) that secures the lower anchor to the C-pillar. Tighten the screw to 39 Nm (29 ft. lbs.). 11. Reinstall the rear seat into the vehicle. Rear Outboard - Quad Cab REAR OUTBOARD - QUAD CAB WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the DaimlerChrysler Mopar(R) Parts Catalog. NOTE: The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. 1. Position the rear outboard seat belt and retractor (4) to the inner C-pillar as a unit. Be certain to engage the hooks on the upper retractor bracket into the mounting hole in the C-pillar. 2. Install and tighten the screw (3) that secures the lower retractor bracket to the C-pillar. Tighten the screw to 39 Nm (29 ft. lbs.). 3. Position the belt web guide (5) to the B-pillar and use hand pressure to press it firmly and evenly until the two clips that secure it snap into place. 4. Reinstall the lower trim (2) onto the inside of the C-pillar. Be certain that the turning loop (1) can be accessed from the face of the lower trim after the seat belt webbing is inserted through the slot in the trim. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Removal > Page 14040 5. Reinstall the upper trim (1) onto the inside of the C-pillar. 6. Position the seat belt turning loop (2) onto the upper C-pillar. 7. Install and tighten the screw (4) that secures the turning loop to the C-pillar. Tighten the screw to 39 Nm (29 ft. lbs.). 8. Engage the upper edge of a new trim cover (3) over the top of the turning loop. Then squeeze the lower end of the trim cover and the turning loop together firmly and evenly until the engagement tabs of the trim cover snap into the slots of the turning loop. 9. Position the seat belt lower anchor (6) to the mounting hole at the base of the C-pillar. 10. Install and tighten the screw (5) that secures the lower anchor to the C-pillar. Tighten the screw to 39 Nm (29 ft. lbs.). 11. Reinstall the rear seat into the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Seat Belt-Tension Reducer-Driver Seat Belt Tensioner: Locations Seat Belt-Tension Reducer-Driver Component ID: 383 Component : SEAT BELT-TENSION REDUCER-DRIVER Connector: Name : SEAT BELT-TENSION REDUCER-DRIVER Color : # of pins : 2 Qualifier : (STANDARD CAB) Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F983 20PK/YL 2 DRIVER SEAT BELT SWITCH SENSE R57 20LG/GY Component Location - 58 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Seat Belt-Tension Reducer-Driver > Page 14045 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Seat Belt-Tension Reducer-Driver > Page 14046 Seat Belt Tensioner: Locations Seat Belt-Tensioner-Driver Component ID: 384 Component : SEAT BELT-TENSIONER-DRIVER Connector: Name : SEAT BELT-TENSIONER-DRIVER Color : BLACK # of pins : 2 Pin Description Circuit 1 DRIVER SEAT BELT TENSIONER LINE 1 R55 20LG/DG 2 DRIVER SEAT BELT TENSIONER LINE 2 R53 20LG/YL Component Location - 58 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Seat Belt-Tension Reducer-Driver > Page 14047 Component Location - 63 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Seat Belt-Tension Reducer-Driver > Page 14048 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Seat Belt-Tension Reducer-Driver > Page 14049 Seat Belt Tensioner: Locations Seat Belt-Tensioner-Passenger Component ID: 385 Component : SEAT BELT-TENSIONER-PASSENGER Connector: Name : SEAT BELT-TENSIONER-PASSENGER Color : BLACK # of pins : 2 Pin Description Circuit 1 PASSENGER SEAT BELT TENSIONER LINE 1R56 20LB/DG 2 PASSENGER SEAT BELT TENSIONER LINE 2R54 20LB/YL Component Location - 61 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Seat Belt-Tension Reducer-Driver > Page 14050 Component Location - 64 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Seat Belt-Tension Reducer-Driver > Page 14051 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Seat Belt-Tension Reducer-Driver Seat Belt Tensioner: Diagrams Seat Belt-Tension Reducer-Driver Component ID: 383 Component : SEAT BELT-TENSION REDUCER-DRIVER Connector: Name : SEAT BELT-TENSION REDUCER-DRIVER Color : # of pins : 2 Qualifier : (STANDARD CAB) Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F983 20PK/YL 2 DRIVER SEAT BELT SWITCH SENSE R57 20LG/GY Component Location - 58 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Seat Belt-Tension Reducer-Driver > Page 14054 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Seat Belt-Tension Reducer-Driver > Page 14055 Seat Belt Tensioner: Diagrams Seat Belt-Tensioner-Driver Component ID: 384 Component : SEAT BELT-TENSIONER-DRIVER Connector: Name : SEAT BELT-TENSIONER-DRIVER Color : BLACK # of pins : 2 Pin Description Circuit 1 DRIVER SEAT BELT TENSIONER LINE 1 R55 20LG/DG 2 DRIVER SEAT BELT TENSIONER LINE 2 R53 20LG/YL Component Location - 58 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Seat Belt-Tension Reducer-Driver > Page 14056 Component Location - 63 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Seat Belt-Tension Reducer-Driver > Page 14057 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Seat Belt-Tension Reducer-Driver > Page 14058 Seat Belt Tensioner: Diagrams Seat Belt-Tensioner-Passenger Component ID: 385 Component : SEAT BELT-TENSIONER-PASSENGER Connector: Name : SEAT BELT-TENSIONER-PASSENGER Color : BLACK # of pins : 2 Pin Description Circuit 1 PASSENGER SEAT BELT TENSIONER LINE 1R56 20LB/DG 2 PASSENGER SEAT BELT TENSIONER LINE 2R54 20LB/YL Component Location - 61 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Seat Belt-Tension Reducer-Driver > Page 14059 Component Location - 64 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Seat Belt-Tension Reducer-Driver > Page 14060 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Seat Belt-Tensioner Seat Belt Tensioner: Description and Operation Seat Belt-Tensioner Description DESCRIPTION Seat belt tensioners supplement the dual front airbags for this vehicle. The seat belt tensioners are integral to the front outboard seat belt retractor units, which are secured to the inner B-pillar on the right and left sides of the vehicle. The retractor is concealed beneath the molded plastic inner B-pillar trim. The seat belt tensioner consists primarily of a sprocket/pinion, a steel tube, a cast metal housing, numerous steel balls, a stamped metal ball trap, a torsion bar and a small pyrotechnically activated gas generator with a connector receptacle. All of these components are located on one side of the retractor spool on the outside of the retractor housing except for the torsion bar, which serves as the spindle upon which the retractor spool rides. The seat belt tensioners are controlled by the Occupant Restraint Controller (ORC) and are connected to the vehicle electrical system through a dedicated take out of the body wire harness by a keyed and latching yellow molded plastic connector insulator to ensure a secure connection. The seat belt tensioners cannot be repaired and, if ineffective or damaged, the entire front seat belt and retractor unit must be replaced. If the front airbags have been deployed, the seat belt tensioners have also been deployed. The seat belt tensioners are not intended for reuse and must be replaced following any front airbag deployment. A growling or grinding sound while attempting to operate the seat belt retractor is a sure indication that the seat belt tensioner has been deployed and requires replacement. Operation OPERATION The seat belt tensioners are deployed in conjunction with the dual front airbags by a signal generated by the Occupant Restraint Controller (ORC) through the driver or passenger seat belt tensioner line 1 and line 2 (or squib) circuits. When the ORC sends the proper electrical signal to the tensioners, the electrical energy generates enough heat to initiate a small pyrotechnic gas generator. The gas generator is installed in one end of a steel tube that contains numerous steel balls. As the gas expands, it pushes the steel balls through the tube into a cast metal housing, where a ball guide directs the balls into engagement with the teeth of a sprocket that is geared to one end of the retractor spool. As the balls drive past the sprocket, the sprocket turns and drives the seat belt retractor spool causing the slack to be removed from the front seat belts. The ball trap captures the balls as they leave the sprocket and are expelled from the housing. Removing excess slack from the front seat belts not only keeps the occupants properly positioned for an airbag deployment following a frontal impact of the vehicle, but also helps to reduce injuries that the occupant might experience in these situations as a result of harmful contact with the steering wheel, steering column, instrument panel or windshield. Also, the seat belt tensioner torsion bar that the retractor spool rides upon is designed to deform in order to control the loading being applied to the occupants by the seat belts during a frontal impact, further reducing the potential for occupant injuries. The ORC monitors the condition of the seat belt tensioners through circuit resistance, and will illuminate the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) and store a Diagnostic Trouble Code (DTC) for any fault that is detected. Proper diagnosis of the seat belt tensioner gas generator and the seat belt tensioner squib circuits requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Seat Belt-Tensioner > Page 14063 Seat Belt Tensioner: Description and Operation Seat Belt Tension Reducer Description DESCRIPTION A seat belt tension reducer is standard equipment for the driver side front outboard seat belt on standard cab versions of this vehicle. The tension reducer is integral to the retractor unit, which is secured to the inner B-pillar on the left side of the vehicle. The retractor is concealed beneath the molded plastic inner B-pillar trim. The seat belt tension reducer consists primarily of a 12-volt Direct Current (DC) solenoid and an integral connector receptacle that is located on the forward facing end housing of the retractor. The seat belt tension reducer is controlled by a battery current output of the ignition switch and a ground path provided by the seat belt switch, and is connected to the vehicle electrical system through a dedicated take out of the body wire harness by a keyed and latching molded plastic connector insulator to ensure a secure connection. The seat belt tension reducer cannot be repaired and, if ineffective or damaged, the entire driver side front outboard seat belt and retractor unit must be replaced. Operation OPERATION The seat belt tension reducer is controlled by a ground signal received from the seat belt switch on the seat belt switch sense circuit and a battery current signal received from the ignition switch on the fused ignition switch output (run-accessory) circuit. When the seat belt switch is closed (the driver side front seat belt is fastened) and the ignition switch is in the ON or ACCESSORY positions, the seat belt tension reducer solenoid is energized. When the solenoid is energized, it actuates a mechanism within the driver side front outboard seat belt retractor to reduce the normal recoil spring tension exerted by the retractor spool, which is designed to reel in the seat belt webbing onto the spool. When the driver side seat belt is unbuckled or if the ignition switch is turned to any position except ON or ACCESSORY, the tension reducer solenoid is de-energized and the normal recoil spring tension of the retractor is restored. The action of the seat belt tension reducer results in improved seat belt comfort for the driver. Reducing the seat belt retractor recoil spring tension is desirable on standard cab versions of this vehicle and not on the quad cab or mega cab versions due to the different mounting position required for the seat belt turning loop on the B-pillar relative to the driver seat position on the standard cab. The seat belt tension reducer as well as the hard wired inputs and outputs of the tension reducer may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Page 14064 Seat Belt Tensioner: Testing and Inspection SEAT BELT TENSION REDUCER Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the seat belt tension reducer from the tension reducer connector receptacle on the driver side front outboard seat belt and retractor unit. Using an ohmmeter, measure the resistance between the seat belt switch sense circuit terminal pin and the fused ignition switch output (run-accessory) circuit terminal pin in the tension reducer connector receptacle on the retractor. Resistance through the tension reducer solenoid coil should be 53 ohms at 20° C (68° F). If OK, go to STEP 2. If not OK, replace the ineffective driver side front outboard seat belt and retractor unit. 2. Check for continuity between the seat belt switch sense circuit cavity of the body wire harness connector for the seat belt tension reducer and a good ground. There should be continuity with the driver side front seat belt buckled, and no continuity with the driver side front seat belt unbuckled. If OK, go to STEP 3. If not OK, repair the shorted or open seat belt switch sense circuit between the tension reducer and the seat belt switch as required. 3. Reconnect the battery negative cable. Check for battery current at the fused ignition switch output (run-accessory) circuit of the body wire harness connector for the seat belt tension reducer. There should be battery current with the ignition switch in the ON or ACCESSORY positions, and no battery current with the ignition switch in any other position. If not OK, repair the shorted or open fused ignition switch output (run-accessory) circuit between the tension reducer and the ignition switch as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations Seat Sensor/Switch: Locations Component ID: 422 Component : SENSOR-SEAT TRACK POSITION-DRIVER Connector: Name : SENSOR-SEAT TRACK POSITION-DRIVER Color : DK. GRAY # of pins : 2 Qualifier : (EXCEPT HEATED SEATS) Pin Description Circuit 1 DRIVER SEAT POSITION SENSOR DATA R261 20LB/TN 2 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/GY Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Page 14068 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Page 14069 Seat Sensor/Switch: Diagrams Component ID: 422 Component : SENSOR-SEAT TRACK POSITION-DRIVER Connector: Name : SENSOR-SEAT TRACK POSITION-DRIVER Color : DK. GRAY # of pins : 2 Qualifier : (EXCEPT HEATED SEATS) Pin Description Circuit 1 DRIVER SEAT POSITION SENSOR DATA R261 20LB/TN 2 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/GY Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Page 14070 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations Air Bag Deactivation Switch: Locations Component ID: 475 Component : SWITCH-PASSENGER AIRBAG ON/OFF Connector: Name : SWITCH-PASSENGER AIRBAG ON/OFF Color : BLACK # of pins : 6 Pin Description Circuit 1 PASSENGER AIRBAG MUX SWITCH SENSE R106 20LG/LB 2 PASSENGER AIRBAG MUX SWITCH RETURN R104 20LB/LG 3 PASSENGER AIRBAG INDICATOR DRIVER G104 20VT/GY 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 5-6-Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 14075 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 14076 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 14077 Air Bag Deactivation Switch: Diagrams Component ID: 475 Component : SWITCH-PASSENGER AIRBAG ON/OFF Connector: Name : SWITCH-PASSENGER AIRBAG ON/OFF Color : BLACK # of pins : 6 Pin Description Circuit 1 PASSENGER AIRBAG MUX SWITCH SENSE R106 20LG/LB 2 PASSENGER AIRBAG MUX SWITCH RETURN R104 20LB/LG 3 PASSENGER AIRBAG INDICATOR DRIVER G104 20VT/GY 4 FUSED IGNITION SWITCH OUTPUT (RUN-START) F201 20PK/OR 5-6-Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 14078 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 14079 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Description Air Bag Deactivation Switch: Description and Operation Description DESCRIPTION The passenger airbag on/off switch (1) is standard equipment on all standard cab versions of this vehicle equipped with the dual front airbag system. This switch is a two-position, resistor multiplexed switch with a single integral amber Light-Emitting Diode (LED), and a non-coded key cylinder-type actuator. The switch is located in the lower right corner of the instrument panel center bezel, near the center of the instrument panel. When the switch is in its installed position, the only components visible through the dedicated opening of the center bezel are the switch bezel (2) and lens, the nomenclature imprinted on the lens, and the key cylinder actuator (3). The OFF position nomenclature of the switch is illuminated and visible only when that switch position is selected. The ON position of the switch is neither visible or illuminated but can be determined by the orientation of the slot of the key cylinder actuator. The remainder of the switch is concealed behind the switch bezel and the instrument panel center bezel. The passenger airbag on/off switch housing is constructed of molded plastic and has three integral mounting tabs. These mounting tabs are used to secure the switch to the back of the molded plastic switch bezel with three small screws. The molded plastic switch bezel also has three integral mounting tabs that are used to secure the switch and bezel unit to the instrument panel center bezel with three additional screws. A molded plastic connector receptacle on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The molded plastic harness connector insulator is keyed and latched to ensure proper and secure switch electrical connections. The passenger airbag on/off switch cannot be adjusted or repaired and, if ineffective or damaged, the switch must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Description > Page 14082 Air Bag Deactivation Switch: Description and Operation Operation OPERATION The passenger airbag on/off switch allows the customer to turn the passenger airbag function ON or OFF to accommodate certain uses of the right front seating position where airbag protection may not be desired. See the owner's manual in the vehicle glove box for specific recommendations on when to enable or disable the passenger airbag. The OFF indicator of the switch will be illuminated whenever the switch is turned to the OFF position and the ignition switch is in the ON position. The ignition key is the only key or object that should ever be inserted into the key cylinder actuator of the switch. The on/off switch requires only a partial key insertion to fully depress a spring-loaded locking plunger. The spring-loaded locking plunger prevents the user from leaving the key in the switch. The key will be automatically ejected when force is not applied. To actuate the passenger airbag on/off switch, insert the ignition key into the switch key actuator far enough to fully depress the plunger, then rotate the actuator to the desired switch position. When the switch key actuator is rotated to its clockwise stop (the key actuator slot will be aligned with the OFF nomenclature), the OFF indicator is illuminated and the passenger airbag is disabled. When the switch is rotated to its counterclockwise stop (the key actuator slot will be in a vertical position) the OFF indicator will be extinguished and the passenger airbag is enabled. The OFF indicator and the enabling or disabling of the passenger airbag is controlled electronically by the Occupant Restraint Controller (ORC) based upon inputs it receives from the on/off switch. The passenger airbag on/off switch connects one of two internal resistors in series between the passenger airbag MUX switch sense and passenger airbag mux switch return circuits of the ORC. The ORC continually monitors the resistance in these circuits to determine the switch position that has been selected. When the switch is in the OFF position, the ORC provides a ground input to the OFF indicator through the passenger airbag indicator driver circuit, which energizes the Light-Emitting Diode (LED) that illuminates the indicator. The ORC will store a Diagnostic Trouble Code (DTC) for any fault it detects in the passenger airbag on/off switch or OFF indicator circuits, and will illuminate the airbag indicator in the instrument cluster if a fault is detected. The hard wired circuits between the passenger airbag on/off switch and the ORC may be diagnosed using conventional diagnostic tools and procedures. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the passenger airbag on/off switch or the electronic controls and communication between other modules and devices that provide some features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the passenger airbag on/off switch or the electronic controls and communication related to passenger airbag on/off switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Service and Repair > Removal Air Bag Deactivation Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: A passenger airbag on/off switch is used only on standard cab vehicles equipped with dual front airbags. Quad cab and mega cab vehicles have a cubby bin installed in the instrument panel center bezel in place of the on/off switch. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the center bezel (1) from the instrument panel. 3. From the back of the center bezel, remove the three screws (2) that secure the passenger airbag on/off switch and bezel unit (3) to the back of the center bezel. 4. Remove the passenger airbag on/off switch and bezel from the center bezel as a unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Service and Repair > Removal > Page 14085 Air Bag Deactivation Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: A passenger airbag on/off switch is used only on standard cab vehicles equipped with dual front airbags. Quad cab and mega cab vehicles have a cubby bin installed in the instrument panel center bezel in place of the on/off switch. 1. Position the passenger airbag on/off switch and bezel unit (3) to the back of the center bezel (1). 2. Install and tighten the three screws (2) that secure the passenger airbag on/off switch bezel to the back of the center bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Reinstall the center bezel onto the instrument panel. 4. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left Impact Sensor: Locations Sensor-Front Impact-Left Component ID: 402 Component : SENSOR-FRONT IMPACT-LEFT Connector: Name : SENSOR-FRONT IMPACT-LEFT Color : YELLOW # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 2 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 14090 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 14091 Impact Sensor: Locations Sensor-Side Impact-Left 1 Component ID: 423 Component : SENSOR-SIDE IMPACT-LEFT 1 Connector: Name : SENSOR-SIDE IMPACT-LEFT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 2 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 3-4-Component Location - 58 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 14092 Component Location - 63 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 14093 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 14094 Impact Sensor: Locations Sensor-Side Impact-Right 1 Component ID: 424 Component : SENSOR-SIDE IMPACT-RIGHT 1 Connector: Name : SENSOR-SIDE IMPACT-RIGHT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 2 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 3-4-Component Location - 61 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 14095 Component Location - 64 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 14096 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left Impact Sensor: Diagrams Sensor-Front Impact-Left Component ID: 402 Component : SENSOR-FRONT IMPACT-LEFT Connector: Name : SENSOR-FRONT IMPACT-LEFT Color : YELLOW # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT 2 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 14099 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 14100 Impact Sensor: Diagrams Sensor-Side Impact-Left 1 Component ID: 423 Component : SENSOR-SIDE IMPACT-LEFT 1 Connector: Name : SENSOR-SIDE IMPACT-LEFT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN 2 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR 3-4-Component Location - 58 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 14101 Component Location - 63 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 14102 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 14103 Impact Sensor: Diagrams Sensor-Side Impact-Right 1 Component ID: 424 Component : SENSOR-SIDE IMPACT-RIGHT 1 Connector: Name : SENSOR-SIDE IMPACT-RIGHT 1 Color : YELLOW # of pins : 4 Pin Description Circuit 1 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG 2 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG 3-4-Component Location - 61 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 14104 Component Location - 64 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 14105 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Description Impact Sensor: Description and Operation Description Front FRONT Two front impact sensors (1) are used on this vehicle, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each front impact sensor is secured with a screw to the back of the right or left end of the lower radiator crossmember within the engine compartment. The sensor housing has an integral connector receptacle (4), an integral anti-rotation pin (3), and an integral mounting hole (2) with a metal sleeve to provide crush protection. The right and left front impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The front impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. The front impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Side SIDE Two side impact sensors (1) are used on this vehicle when it is equipped with the optional side curtain airbags, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each side sensor is secured with a nut within the right or left B-pillar just above the front seat belt retractors and behind the lower B-pillar trim within the passenger compartment. The sensor housing has an integral connector receptacle (2), an integral mounting stud (3), and an integral anti-rotation pin. The right and left side impact sensors are identical in construction and calibration. A cavity in the center of the molded plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The side impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Description > Page 14108 Impact Sensor: Description and Operation Operation Front FRONT The front impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the front impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to front impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Side SIDE The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through left or right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the side impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to side impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal Impact Sensor: Service and Repair Removal Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front supplemental restraints. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front supplemental restraint deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the screw (4) that secures the right or left front impact sensor (3) to the back of the right or left end of the lower radiator crossmember (1). 3. Disconnect the headlamp and dash wire harness connector (2) from the sensor connector receptacle. 4. Remove the right or left front impact sensor from the engine compartment. Side - Mega Cab SIDE - MEGA CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side curtain airbags. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 14111 1. Adjust the front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the nut (3) that secures the stud of the side impact sensor (4) to the inner B-pillar (2). 4. Reach through the large hole above the retractor mounting hole in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 5. Pull the side impact sensor out through the large hole in the B-pillar far enough to access and disconnect the body wire harness connector (1) from the sensor connector receptacle. 6. Remove the side impact sensor from the B-pillar. Side - Quad Cab SIDE - QUAD CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side curtain airbags. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 14112 1. Adjust the front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the nut (3) that secures the stud of the side impact sensor (2) to the inner B-pillar (1). 4. Reach through the large hole above the retractor mounting hole in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 5. Pull the side impact sensor out through the large hole in the B-pillar far enough to access and disconnect the body wire harness connector (4) from the sensor connector receptacle. 6. Remove the side impact sensor from the B-pillar. Side - Standard Cab SIDE - STANDARD CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side curtain airbags. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. 1. Adjust the driver or passenger side front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the front outboard seat belt and retractor from the inside of the B-pillar. 4. Remove the nut (4) that secures the stud of the side impact sensor (1) to the inner B-pillar. 5. Reach through the retractor mounting hole (3) in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 6. Pull the side impact sensor out of the B-pillar far enough to access and disconnect the body wire harness connector (2) from the sensor connector receptacle. 7. Remove the sensor from the B-pillar. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 14113 Impact Sensor: Service and Repair Installation Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front supplemental restraints. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front supplemental restraint deployment. 1. Position the right or left front impact sensor (3) into the engine compartment. 2. Reconnect the headlamp and dash wire harness connector (2) to the sensor connector receptacle. 3. Carefully position the sensor onto the back of the right or left end of the lower radiator crossmember (1). Be certain that the anti-rotation pin on the back of the sensor is engaged in the clearance hole of the crossmember. 4. Install and tighten the screw (4) that secures the sensor to the back of the crossmember. Tighten the screw to 10 Nm (90 in. lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Side - Mega Cab SIDE - MEGA CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side curtain airbags. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 14114 1. Position the side impact sensor (4) to the large hole above the retractor mounting hole in the inner B-pillar (2). 2. Reconnect the body wire harness connector (1) to the sensor connector receptacle. 3. Reach through the large hole above the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (3) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 Nm (70 in. lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Side - Quad Cab SIDE - QUAD CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side curtain airbags. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. 1. Position the side impact sensor (2) to the large hole above the retractor mounting hole in the inner B-pillar (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 14115 2. Reconnect the body wire harness connector (4) to the sensor connector receptacle. 3. Reach through the large hole above the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (3) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 Nm (70 in. lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Side - Standard Cab SIDE - STANDARD CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side curtain airbags. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper supplemental restraint deployment. 1. Position the side impact sensor (1) to the retractor mounting hole (3) in the inner B-pillar. 2. Reconnect the body wire harness connector (2) to the sensor connector receptacle. 3. Reach through the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (4) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 Nm (70 in. lbs.). 5. Reinstall the front outboard seat belt and retractor to the inside of the B-pillar. 6. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Component ID: 483 Component : SWITCH-SEAT BELT-DRIVER Connector: Name : SWITCH-SEAT BELT-DRIVER Color : # of pins : 2 Qualifier : (HD) Pin Description Circuit 1 GROUND Z951 18BK 2 SEAT BELT SWITCH SENSE G10 20VT/LG Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 14119 Connector: Name : SWITCH-SEAT BELT-DRIVER Color : LT. GRAY # of pins : 2 Qualifier : (LD) Pin Description Circuit 1 GROUND Z917 20BK 2 DRIVER SEAT BELT SWITCH SENSE R57 20LG/GY Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 14120 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 14121 Seat Belt Buckle Switch: Diagrams Component ID: 483 Component : SWITCH-SEAT BELT-DRIVER Connector: Name : SWITCH-SEAT BELT-DRIVER Color : # of pins : 2 Qualifier : (HD) Pin Description Circuit 1 GROUND Z951 18BK 2 SEAT BELT SWITCH SENSE G10 20VT/LG Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 14122 Connector: Name : SWITCH-SEAT BELT-DRIVER Color : LT. GRAY # of pins : 2 Qualifier : (LD) Pin Description Circuit 1 GROUND Z917 20BK 2 DRIVER SEAT BELT SWITCH SENSE R57 20LG/GY Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 14123 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Description Seat Belt Buckle Switch: Description and Operation Description DESCRIPTION All vehicles are equipped with a driver side seat belt switch that is a small, normally open, single pole, single throw, leaf contact, momentary switch. The driver side seat belt switch is integral to the buckle (1) of the driver side front seat belt buckle, which is located on a stamped steel stanchion secured by a screw (3) to the inboard side of the driver side front seat cushion frame. The seat belt switch is connected to the vehicle electrical system through a two-lead pigtail wire and connector (4) on the seat belt buckle-half, which is connected to a wire harness connector and take out of the seat wire harness routed beneath the driver side front seat cushion in the passenger compartment. The seat belt switch cannot be adjusted or repaired. If ineffective or damaged, the entire driver side front seat belt buckle-half unit must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Description > Page 14126 Seat Belt Buckle Switch: Description and Operation Operation OPERATION The driver side seat belt switch is designed to control a path to ground for the seat belt switch sense input of the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). When the driver side front seat belt tip-half is inserted into the seat belt buckle, the switch closes the path to ground; and, when the driver side front seat belt tip-half is removed from the seat belt buckle, the switch opens the ground path. The switch is actuated by the latch mechanism within the seat belt buckle. The seat belt switch is connected in series between ground and the seat belt switch sense input of the instrument cluster. The seat belt switch receives ground at all times through its pigtail wire connection to the seat wire harness from a take out of the body wire harness. An eyelet terminal connector on the body wire harness ground take out is secured beneath a ground screw on the left cowl side inner panel, beneath the instrument panel. The seat belt switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Description and Operation > Description Seat Position Sensor: Description and Operation Description DESCRIPTION The seat track position sensor (2) is a Hall Effect-type sensor used on some vehicles. This sensor consists of a Hall Effect Integrated Circuit (IC) chip encased in potting material within a cavity of the molded plastic sensor housing. The sensor housing has a mounting slot containing an integral latch feature (1) and slides and latches onto a stamped metal blade-type bracket located on the inboard side of the upper inboard seat adjuster track near the rear of the driver side front seat. A molded connector receptacle (3) integral to the sensor housing is connected to the vehicle electrical system through a connector and take out of the driver seat wire harness beneath the front seat cushion frame. The seat track position sensor cannot be adjusted or repaired and, if ineffective or damaged, the entire sensor must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Description and Operation > Description > Page 14131 Seat Position Sensor: Description and Operation Operation OPERATION The seat track position sensor is designed to provide a seat position data input to the Occupant Restraint Controller (ORC) indicating whether the driver side front seat is in a full forward or a not full forward position. The ORC uses this data as an additional logic input for use in determining the appropriate deployment force to be used when deploying the multistage driver side front airbag. The seat track position sensor receives a nominal five volt supply from the ORC. The sensor communicates the seat position by modulating the voltage returned to the ORC on a sensor data circuit. The ORC also monitors the condition of the sensor circuits and will store a Diagnostic Trouble Code (DTC) for any fault that is detected, and sends messages over the Controller Area Network (CAN) data bus to illuminate the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The hard wired circuits between the seat track position sensor and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the seat track position sensor or the electronic controls and communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the seat track position sensor or the electronic controls and communication related to seat track position sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Removal Seat Position Sensor: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Reach under the front seat cushion to access the seat track position sensor (2) on a bracket (1) located on the inboard side near the rear of the upper inboard driver seat track (4). 3. Using a small screwdriver, hold the latch feature (3) depressed while sliding the connector end of the sensor off of the bracket. 4. Disconnect the seat wire harness connector (5) from the sensor connector receptacle. 5. Remove the sensor from under the front seat. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Removal > Page 14134 Seat Position Sensor: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Reach under the driver side front seat cushion to reconnect the seat wire harness connector (5) to the seat track position sensor (2) connector receptacle. Be certain that the latch on the connector is fully engaged. 2. Align the open end of the sensor to the slide tab of the sensor bracket (1) located on the inboard side near the rear of the upper inboard driver seat track (4). 3. Push the sensor firmly onto the bracket until the latch feature (3) snaps into place with an audible click. 4. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations Seat Sensor/Switch: Locations Component ID: 422 Component : SENSOR-SEAT TRACK POSITION-DRIVER Connector: Name : SENSOR-SEAT TRACK POSITION-DRIVER Color : DK. GRAY # of pins : 2 Qualifier : (EXCEPT HEATED SEATS) Pin Description Circuit 1 DRIVER SEAT POSITION SENSOR DATA R261 20LB/TN 2 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/GY Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 14138 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 14139 Seat Sensor/Switch: Diagrams Component ID: 422 Component : SENSOR-SEAT TRACK POSITION-DRIVER Connector: Name : SENSOR-SEAT TRACK POSITION-DRIVER Color : DK. GRAY # of pins : 2 Qualifier : (EXCEPT HEATED SEATS) Pin Description Circuit 1 DRIVER SEAT POSITION SENSOR DATA R261 20LB/TN 2 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/GY Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 14140 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Service and Repair > Removal Antenna, Navigation: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel top cover. 3. Remove the radio. 4. Remove the antenna mounting fasteners. 5. Cut each end of the cable (1) and leave remaining portion in the instrument panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Service and Repair > Removal > Page 14147 Antenna, Navigation: Service and Repair Installation INSTALLATION 1. Position new antenna cable to wire harness. Secure into place. 2. Install antenna mounting fasteners. 3. Install radio. 4. Install instrument panel top cover. 5. Connect battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Keyless Start Antenna > Component Information > Technical Service Bulletins > Remote Start System - Antenna Diagnostic Chart Keyless Start Antenna: Technical Service Bulletins Remote Start System - Antenna Diagnostic Chart NUMBER: 08-003-07 GROUP: Electrical DATE: January 27, 2007 SUBJECT: Remote Start System - Diagnostic Chart For Antenna OVERVIEW: This bulletin involves a diagnostic chart that may be used to aid the technician with the diagnosis of the antenna on an originally equipped (factory installed) remote start system. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2006-2007 (HB/HG) Durango/Aspen 2007 (JS) Sebring/Avenger 2007 (KA) Nitro 2007 (ND) Dakota 2007 (WK) Grand Cherokee 2007 (XK) Commander NOTE: This bulletin applies to vehicles with an original equipment Remote Start system (sales code XBM). DISCUSSION: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Keyless Start Antenna > Component Information > Technical Service Bulletins > Remote Start System - Antenna Diagnostic Chart > Page 14152 The customer may notice that the signal range of the Remote Keyless Entry (RKE) system is reduced. The RKE key fob may need to be closer than 3 meters (10 feet) before the functions available on the key fob will operate. This condition may be due to the RKE antenna. The diagnostic flow chart is provide as a diagnostic aid for dealer technician (Fig. 1). POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Cable - Instrument Panel Antenna Cable: Service and Repair Antenna Cable - Instrument Panel Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the glove box. 3. Remove the instrument panel center bezel. 4. Remove the radio. CAUTION: Pulling the antenna cable straight out of the radio without pulling on the locking antenna connector could damage the cable or radio. 5. Disconnect the antenna cable by pulling the locking antenna connector away from the radio. 6. Remove antenna cable from instrument panel by pulling on retaining fasteners. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Cable - Instrument Panel > Page 14158 1. Install antenna cable (1) to instrument panel by pressing retaining fasteners into position. 2. Connect instrument panel antenna cable to antenna body and cable (2). 3. Install radio. 4. Install the instrument panel center bezel. 5. Install the glove box. 6. Connect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Cable - Instrument Panel > Page 14159 Antenna Cable: Service and Repair Cable-Satellite Antenna Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Lower the rear portion of the headliner as necessary to access the underside of the satellite antenna (2). 3. Remove the B-pillar upper trim panel. 4. Remove the B-pillar lower trim panel. 5. Move carpet to access cable (1). 6. Disconnect each end of the cable. Installation INSTALLATION 1. Connect each end of the cable (1). 2. Place carpet into position. 3. Install the B-pillar lower trim panel. 4. Install the B-pillar upper trim panel Remove the C-pillar upper trim panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Cable - Instrument Panel > Page 14160 5. Install the headliner. 6. Connect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest for Alarm Module: > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood Alarm Module: Customer Interest Antitheft System - Goes Off When Opening The Hood NUMBER: 08-040-06 GROUP: Electrical DATE: September 06, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: Vehicle Theft Security System Alarm May Alert When Hood Is Opened OVERVIEW: This bulletin involves selectively erasing and reprogramming the Cabin Compartment Node Module (CCN) with new software. MODELS: 2007 (DR/DH/D1/DC) Ram Truck NOTE: This bulletin applies to vehicles equipped with a remote start system (sales code XBM) prior to October 10, 2006 (MDH 1010XX). SYMPTOM/CONDITION: The Vehicle Theft Security System (VTSS) may alert (flash lights and/or sound horn) if one of the following occurs: a. The customer arms the VTSS and then reaches through an open window, pulls on the hood release, and fully opens the vehicle hood. b. The customer releases the hood but not enough to open the hood ajar switch, arms the VTSS, and then fully opens the vehicle hood. c. The customer opens the hood, arms the VTSS, the vehicle communications bus goes in to "sleep mode" (may take 10 minutes), then the "LOCK" button on the key fob is depressed. The hood ajar switch is not part of the VTSS used on domestic use vehicles. The hood ajar switch is used for export vehicles equipped with the Vehicle Theft Alarm (VTA) system. DIAGNOSIS: 1. Connect the StarSCAN(R) to the vehicle. 2. Power up the StarSCAN(R) and obtain the HOME menu. 3. From the HOME menu select "ECU VIEW". 4. Select "CCN - Cabin Compartment". 5. Select "More Options". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest for Alarm Module: > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 14170 6. Select "ECU Flash" 7. Read and record the software part number that is display with "Resident Flash File For Part". 8. Is the software part number 05172187AC (or later)? a. If YES >>> then STOP. This bulletin does not apply. Further diagnosis is required. b. If NO >>> then perform the Repair Procedure. NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the CCN in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash CCN" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest for Alarm Module: > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 14171 13. Highlight the listed calibration. 14. Select "Update Controller". Follow on screen instructions. 15. When the CCN update is complete, select "OK". 16. Verify the part number at the top of the "Flash CCN" screen has updated to the new part number. NOTE: Due to the CCN programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alarm Module: > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood Alarm Module: All Technical Service Bulletins Antitheft System - Goes Off When Opening The Hood NUMBER: 08-040-06 GROUP: Electrical DATE: September 06, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: Vehicle Theft Security System Alarm May Alert When Hood Is Opened OVERVIEW: This bulletin involves selectively erasing and reprogramming the Cabin Compartment Node Module (CCN) with new software. MODELS: 2007 (DR/DH/D1/DC) Ram Truck NOTE: This bulletin applies to vehicles equipped with a remote start system (sales code XBM) prior to October 10, 2006 (MDH 1010XX). SYMPTOM/CONDITION: The Vehicle Theft Security System (VTSS) may alert (flash lights and/or sound horn) if one of the following occurs: a. The customer arms the VTSS and then reaches through an open window, pulls on the hood release, and fully opens the vehicle hood. b. The customer releases the hood but not enough to open the hood ajar switch, arms the VTSS, and then fully opens the vehicle hood. c. The customer opens the hood, arms the VTSS, the vehicle communications bus goes in to "sleep mode" (may take 10 minutes), then the "LOCK" button on the key fob is depressed. The hood ajar switch is not part of the VTSS used on domestic use vehicles. The hood ajar switch is used for export vehicles equipped with the Vehicle Theft Alarm (VTA) system. DIAGNOSIS: 1. Connect the StarSCAN(R) to the vehicle. 2. Power up the StarSCAN(R) and obtain the HOME menu. 3. From the HOME menu select "ECU VIEW". 4. Select "CCN - Cabin Compartment". 5. Select "More Options". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alarm Module: > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 14177 6. Select "ECU Flash" 7. Read and record the software part number that is display with "Resident Flash File For Part". 8. Is the software part number 05172187AC (or later)? a. If YES >>> then STOP. This bulletin does not apply. Further diagnosis is required. b. If NO >>> then perform the Repair Procedure. NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the CCN in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash CCN" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alarm Module: > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 14178 13. Highlight the listed calibration. 14. Select "Update Controller". Follow on screen instructions. 15. When the CCN update is complete, select "OK". 16. Verify the part number at the top of the "Flash CCN" screen has updated to the new part number. NOTE: Due to the CCN programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Description and Operation > Description Alarm System Transponder: Description and Operation Description DESCRIPTION Each ignition key (2) used in the Sentry Key Immobilizer System (SKIS) has a transponder chip included on the circuit board (4) beneath the cover (1) of the integral Remote Keyless Entry (RKE) transmitter (3). In addition to having to be cut to match the mechanical coding of the ignition lock cylinder and programmed for operation of the RKE system, each new Sentry Key has a unique transponder identification code that is permanently programmed into it by the manufacturer, and which must be programmed into the Sentry Key REmote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) to be recognized by the SKIS as a valid key. The Sentry Key transponder cannot be adjusted or repaired. If ineffective or damaged, the entire key and RKE transmitter unit must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Description and Operation > Description > Page 14183 Alarm System Transponder: Description and Operation Operation OPERATION When the ignition switch is turned to the ON position, the Sentry Key REmote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) communicates through its antenna with the Sentry Key transponder using a Radio Frequency (RF) signal. The SKREEM then listens for a RF response from the transponder through the same antenna. The Sentry Key transponder chip is within the range of the SKREEM transceiver antenna ring when it is inserted into the ignition lock cylinder. The SKREEM determines whether a valid key is present in the ignition lock cylinder based upon the response from the transponder. If a valid key is detected, that fact is communicated by the SKREEM to the Powertrain Control Module (PCM)/Engine Control Module (ECM) over the Controller Area Network (CAN) data bus, and the PCM/ECM allows the engine to continue running. If the PCM/ECM receives an invalid key message, or receives no message from the SKREEM over the CAN data bus, the engine will be disabled after about two seconds of operation. The ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) will also respond to the invalid key message on the CAN data bus by flashing the security indicator ON and OFF. Each Sentry Key has a unique transponder identification code permanently programmed into it by the manufacturer. Likewise, the SKREEM has a unique Secret Key code programmed into it by the manufacturer. When a Sentry Key is programmed into the memory of the SKREEM, the SKREEM stores the transponder identification code from the Sentry Key, and the Sentry Key learns the Secret Key code from the SKREEM. Once the Sentry Key learns the Secret Key code of the SKREEM, it is permanently stored in the memory of the transponder. Therefore, once a Sentry Key has been programmed to a particular vehicle, it cannot be used on any other vehicle. The SKIS performs a self-test each time the ignition switch is turned to the ON position, and will store key-related fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM memory if a Sentry Key transponder problem is detected. The Sentry Key transponder chip can be diagnosed, and any stored DTC can be retrieved using a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Customer Interest for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood Hood Sensor/Switch (For Alarm): Customer Interest Antitheft System - Goes Off When Opening The Hood NUMBER: 08-040-06 GROUP: Electrical DATE: September 06, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: Vehicle Theft Security System Alarm May Alert When Hood Is Opened OVERVIEW: This bulletin involves selectively erasing and reprogramming the Cabin Compartment Node Module (CCN) with new software. MODELS: 2007 (DR/DH/D1/DC) Ram Truck NOTE: This bulletin applies to vehicles equipped with a remote start system (sales code XBM) prior to October 10, 2006 (MDH 1010XX). SYMPTOM/CONDITION: The Vehicle Theft Security System (VTSS) may alert (flash lights and/or sound horn) if one of the following occurs: a. The customer arms the VTSS and then reaches through an open window, pulls on the hood release, and fully opens the vehicle hood. b. The customer releases the hood but not enough to open the hood ajar switch, arms the VTSS, and then fully opens the vehicle hood. c. The customer opens the hood, arms the VTSS, the vehicle communications bus goes in to "sleep mode" (may take 10 minutes), then the "LOCK" button on the key fob is depressed. The hood ajar switch is not part of the VTSS used on domestic use vehicles. The hood ajar switch is used for export vehicles equipped with the Vehicle Theft Alarm (VTA) system. DIAGNOSIS: 1. Connect the StarSCAN(R) to the vehicle. 2. Power up the StarSCAN(R) and obtain the HOME menu. 3. From the HOME menu select "ECU VIEW". 4. Select "CCN - Cabin Compartment". 5. Select "More Options". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Customer Interest for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 14192 6. Select "ECU Flash" 7. Read and record the software part number that is display with "Resident Flash File For Part". 8. Is the software part number 05172187AC (or later)? a. If YES >>> then STOP. This bulletin does not apply. Further diagnosis is required. b. If NO >>> then perform the Repair Procedure. NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the CCN in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash CCN" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Customer Interest for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 14193 13. Highlight the listed calibration. 14. Select "Update Controller". Follow on screen instructions. 15. When the CCN update is complete, select "OK". 16. Verify the part number at the top of the "Flash CCN" screen has updated to the new part number. NOTE: Due to the CCN programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood Hood Sensor/Switch (For Alarm): All Technical Service Bulletins Antitheft System - Goes Off When Opening The Hood NUMBER: 08-040-06 GROUP: Electrical DATE: September 06, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: Vehicle Theft Security System Alarm May Alert When Hood Is Opened OVERVIEW: This bulletin involves selectively erasing and reprogramming the Cabin Compartment Node Module (CCN) with new software. MODELS: 2007 (DR/DH/D1/DC) Ram Truck NOTE: This bulletin applies to vehicles equipped with a remote start system (sales code XBM) prior to October 10, 2006 (MDH 1010XX). SYMPTOM/CONDITION: The Vehicle Theft Security System (VTSS) may alert (flash lights and/or sound horn) if one of the following occurs: a. The customer arms the VTSS and then reaches through an open window, pulls on the hood release, and fully opens the vehicle hood. b. The customer releases the hood but not enough to open the hood ajar switch, arms the VTSS, and then fully opens the vehicle hood. c. The customer opens the hood, arms the VTSS, the vehicle communications bus goes in to "sleep mode" (may take 10 minutes), then the "LOCK" button on the key fob is depressed. The hood ajar switch is not part of the VTSS used on domestic use vehicles. The hood ajar switch is used for export vehicles equipped with the Vehicle Theft Alarm (VTA) system. DIAGNOSIS: 1. Connect the StarSCAN(R) to the vehicle. 2. Power up the StarSCAN(R) and obtain the HOME menu. 3. From the HOME menu select "ECU VIEW". 4. Select "CCN - Cabin Compartment". 5. Select "More Options". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 14199 6. Select "ECU Flash" 7. Read and record the software part number that is display with "Resident Flash File For Part". 8. Is the software part number 05172187AC (or later)? a. If YES >>> then STOP. This bulletin does not apply. Further diagnosis is required. b. If NO >>> then perform the Repair Procedure. NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the CCN in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash CCN" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 14200 13. Highlight the listed calibration. 14. Select "Update Controller". Follow on screen instructions. 15. When the CCN update is complete, select "OK". 16. Verify the part number at the top of the "Flash CCN" screen has updated to the new part number. NOTE: Due to the CCN programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 14201 Hood Sensor/Switch (For Alarm): Locations Component ID: 469 Component : SWITCH-HOOD AJAR Connector: Name : SWITCH-HOOD AJAR Color : # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 HOOD AJAR SWITCH SENSE G70 20VT/LB 2 AAT RETURN G930 20VT/TN Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 14202 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 14203 Hood Sensor/Switch (For Alarm): Diagrams Component ID: 469 Component : SWITCH-HOOD AJAR Connector: Name : SWITCH-HOOD AJAR Color : # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 HOOD AJAR SWITCH SENSE G70 20VT/LB 2 AAT RETURN G930 20VT/TN Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 14204 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Description Hood Sensor/Switch (For Alarm): Description and Operation Description DESCRIPTION The hood ajar switch is a normally closed, single pole, spring-loaded plunger actuated switch. This switch has two unique versions that are used in two different applications. One switch is used only on vehicles equipped with the Vehicle Theft Alarm (VTA) system for sale in certain export markets where protection of the underhood area is required equipment. The second switch is used only on domestic vehicles equipped with an optional remote starter system. The molded plastic switch body (5) has an integral molded connector receptacle (1) on the lower end containing two terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the headlamp and dash wire harness. Two integral latches (2) lock the switch into a keyed mounting hole in the stamped steel switch mounting bracket. The mounting bracket is secured with screws to the inboard side of the right front fender load beam within the engine compartment. A molded plastic striker secured to the underside of the hood panel inner reinforcement actuates the switch plunger as the hood panel is closed. The switch plunger (3) extends through a mounting collar (4) and a sleeve-like retainer ring on the upper end of the switch body. The retainer ring has a one time, self-adjustment feature that is activated after the switch is installed by closing the hood. The retainer ring is also color-coded to aid in identifying the switch application. A dark brown retainer ring identifies the underhood security switch application, while a white retainer ring identifies the remote starter system application. An installed hood ajar switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or requires readjustment, it must be replaced with a new unit. The hood ajar switch striker is not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced with a new unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Description > Page 14207 Hood Sensor/Switch (For Alarm): Description and Operation Operation OPERATION The hood ajar switches are interchangeable physically, but not functionally. In each case, the hood ajar switch is a normally closed switch that is held open as the spring-loaded switch plunger is depressed by the striker on the inner hood panel reinforcement when the hood panel is closed and latched. When the hood is opened, the spring-loaded switch plunger extends from the switch body and the switch contacts are closed. In the underhood security application (export vehicles only - dark brown retainer ring), the switch is connected in series between ground and the hood ajar switch sense input of the Totally Integrated Power Module (TIPM). The TIPM uses an internal resistor pull up to monitor the state of the hood ajar switch contacts. In the remote starter system application (domestic vehicles only - white retainer ring) the switch has a 1 kilo ohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between an output of the TIPM and the hood ajar switch sense input of the TIPM. The TIPM continually monitors this circuit and will store a Diagnostic Trouble Code (DTC) for any fault that it detects. The components of the switch self-adjustment feature include an integral stop on the shaft of the plunger and a ribbed, ratcheting sleeve-like retainer ring at the top of the switch body from which the plunger extends. With the switch mounting collar secured in its mounting bracket, the plunger is depressed by the striker on the hood inner reinforcement as the hood is closed. As the plunger is depressed, the plunger stop contacts the top of the retainer ring and it is driven downward, ratcheting through the switch mounting collar until the hood is fully closed and latched. The ribs on the retainer ring are engaged within the mounting collar to maintain this adjusted position. The hood ajar switch as well as the hard wired circuits between the switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between modules and other devices related to hood ajar switch operation that provide some features of the export vehicle theft or domestic remote starter systems. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to hood ajar switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal Hood Sensor/Switch (For Alarm): Service and Repair Removal Striker STRIKER NOTE: The hood ajar switch striker is not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Unlatch and open the hood. 2. Using a trim stick or another suitable wide flat-bladed tool, pry the rearward end of the hood ajar switch striker (2) away from the inner hood panel reinforcement (1) far enough to disengage the integral retainers from their mounting holes. 3. Remove the striker from the inner hood panel reinforcement and discard. Bracket BRACKET 1. Remove the hood ajar switch (2) from the mounting bracket (3). 2. Remove the two screws (4) that secure the hood ajar switch bracket to the two rivet nuts (1) in the right front load beam (6). 3. Remove the hood ajar switch mounting bracket from the inboard side of the right front load beam. Switch SWITCH Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal > Page 14210 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. From the top of the mounting bracket (3) on the right front load beam (6), squeeze the two hood ajar switch (2) latch tabs together and pull the switch upward. 4. Pull the hood ajar switch up through the hole in the mounting bracket far enough to access and disconnect the jumper wire harness connector (5) from the switch connector receptacle. 5. Remove the hood ajar switch from the mounting bracket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal > Page 14211 Hood Sensor/Switch (For Alarm): Service and Repair Installation Striker STRIKER NOTE: The hood ajar switch striker cap is not intended for reuse. If the striker cap is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Position the new hood ajar switch striker (2) to the mounting holes in the inner hood panel reinforcement (1) over the hood ajar switch (3). 2. Using hand pressure, press the hood ajar switch striker upward into the mounting holes in the inner hood panel reinforcement until both integral retainers are fully engaged. 3. Close and latch the hood. Bracket BRACKET 1. Check to be certain that the two rivet nuts (1) on the inboard side of the right front load beam (6) are in good condition and properly secured. 2. Position the hood ajar switch mounting bracket (3) onto the right front load beam. 3. Install and tighten the two screws (4) that secure the mounting bracket to the load beam. Beginning with the rearward screw, tighten both screws to 8 Nm (71 in. lbs.). 4. Reinstall the hood ajar switch (2) into the mounting bracket. Switch Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal > Page 14212 SWITCH 1. Position the hood ajar switch (2) near the hole in the mounting bracket (3) on the right front load beam (6). 2. Route the jumper wire harness connector (5) through the switch mounting bracket and reconnect it to the switch connector receptacle. 3. From the top of the mounting bracket, press the switch downward into the mounting hole until the integral switch latch tabs lock it into place. 4. Reconnect the battery negative cable. 5. Close and latch the hood. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Component ID: 211 Component : MODULE-SENTRY KEY REMOTE ENTRY Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z109 20BK/GY 5 FUSED B(+) A114 18GY/RD 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT 8-Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 14217 Component Location - 41 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 14218 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 14219 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 14220 Keyless Entry Module: Diagrams Component ID: 211 Component : MODULE-SENTRY KEY REMOTE ENTRY Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z109 20BK/GY 5 FUSED B(+) A114 18GY/RD 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT 8-Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 14221 Component Location - 41 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 14222 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 14223 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry Keyless Entry Module: Description and Operation Module-Remote Keyless Entry Description DESCRIPTION When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 Km/h(15 mph) will also cancel the panic event. Operation OPERATION Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 14226 Keyless Entry Module: Description and Operation Sentry Key Remote Entry Module Description DESCRIPTION The Sentry Key REmote Entry Module (SKREEM) (1) is sometimes referred to as the Wireless Control Module (WCM). The SKREEM is the primary component of the Sentry Key Immobilizer System (SKIS). It is also the receiver for the Remote Keyless Entry (RKE) system. The SKREEM is located on the right side of the steering column, near the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM has an integral molded plastic halo-like antenna ring (4) that extends from the bottom. When the SKREEM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle (3) is located just behind the antenna ring on the bottom of the SKREEM housing. An integral molded plastic mounting tab (2) on the rear corner of the SKREEM housing has a hole in the center through which a screw passes to secure the unit to the steering column. The SKREEM is connected to the vehicle electrical system through a single take out and connector of the instrument panel wire harness. Two SKREEM modules are used: one for vehicles equipped with RKE only, and one for vehicles equipped with RKE and SKIS. The SKREEM cannot be adjusted or repaired. If ineffective or damaged, the entire SKREEM unit must be replaced. Operation OPERATION The Sentry Key REmote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver. The SKREEM communicates over the Controller Area Network (CAN) data bus with the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), the Powertrain Control Module (PCM)/Engine Control Module (ECM) or the diagnostic scan tool. The SKREEM and the PCM/ECM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS) disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKREEM or the PCM/ECM. However, the use of this strategy also means that replacement of either the SKREEM or the PCM/ECM units will require a system initialization procedure to restore system operation. The SKREEM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM. For added system security, each SKREEM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM or ECM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM. Therefore, the Secret Key code is a common element that is found in every component of the SKIS. Another security code called a PIN, is used to gain access to the SKREEM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKREEM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM or ECM during SKIS initialization. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 14227 In the event that a SKREEM replacement is required, the Secret Key code can be transferred to the new SKREEM from the PCM or ECM using a diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the ON position, the SKREEM transmits an RF signal to excite the transponder in the ignition key. The SKREEM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM sends an electronic valid key message to the PCM/ECM over the CAN bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the SKREEM sends an invalid key message to the PCM/ECM. The PCM/ECM will enable or disable engine operation based upon the status of the SKREEM messages. It is important to note that the default condition in the PCM or ECM is an invalid key; therefore, if no message is received from the SKREEM by the PCM or ECM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM also sends security indicator request messages to the EMIC over the CAN data bus to tell the EMIC how to operate the security indicator. The security indicator request message from the SKREEM tells the EMIC to turn the indicator ON for about three seconds each time the ignition switch is turned to the ON position as a bulb test. After completion of the bulb test, the SKREEM sends security indicator request messages to the EMIC to turn the indicator OFF, turn the indicator ON, or to flash the indicator ON and OFF. If the security indicator flashes or stays ON solid after the bulb test, it signifies a SKIS fault. If the SKREEM detects a system malfunction or the SKIS has become ineffective, the security indicator will stay ON solid. If the SKREEM detects an invalid key or if a key transponder-related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM will also send messages to the EMIC to flash the security indicator whenever the Customer Learn programming mode is being utilized. The SKIS performs a self-test each time the ignition switch is turned to the ON position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM memory if a system malfunction is detected. The hard wired circuits of the SKREEM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SKREEM or the electronic controls or communication between other modules and devices that provide some features of the SKIS. The most reliable, efficient, and accurate means to diagnose the SKREEM or the electronic controls and communication related to SKREEM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Description and Operation > Page 14228 Keyless Entry Module: Testing and Inspection REMOTE KEYLESS ENTRY MODULE The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Removal Keyless Entry Module: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, push inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 14231 8. Disconnect the wire harness connector (2) from the Sentry Key REmote Entry Module (SKREEM) (1). 9. Remove the screw (3) that secures the SKREEM (1) to the steering column (2). 10. Disengage the antenna ring from around the ignition lock cylinder housing and remove the SKREEM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 14232 Keyless Entry Module: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the Sentry Key REmote Entry Module (SKREEM) (1) onto the steering column (2) with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw (3) that secures the SKREEM to the steering column housing. Tighten the screw to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the SKREEM (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 14233 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). 10. Reconnect the battery negative cable. NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS) if the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > Keyless Start Antenna > Component Information > Technical Service Bulletins > Remote Start System - Antenna Diagnostic Chart Keyless Start Antenna: Technical Service Bulletins Remote Start System - Antenna Diagnostic Chart NUMBER: 08-003-07 GROUP: Electrical DATE: January 27, 2007 SUBJECT: Remote Start System - Diagnostic Chart For Antenna OVERVIEW: This bulletin involves a diagnostic chart that may be used to aid the technician with the diagnosis of the antenna on an originally equipped (factory installed) remote start system. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2006-2007 (HB/HG) Durango/Aspen 2007 (JS) Sebring/Avenger 2007 (KA) Nitro 2007 (ND) Dakota 2007 (WK) Grand Cherokee 2007 (XK) Commander NOTE: This bulletin applies to vehicles with an original equipment Remote Start system (sales code XBM). DISCUSSION: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > Keyless Start Antenna > Component Information > Technical Service Bulletins > Remote Start System - Antenna Diagnostic Chart > Page 14239 The customer may notice that the signal range of the Remote Keyless Entry (RKE) system is reduced. The RKE key fob may need to be closer than 3 meters (10 feet) before the functions available on the key fob will operate. This condition may be due to the RKE antenna. The diagnostic flow chart is provide as a diagnostic aid for dealer technician (Fig. 1). POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Specifications Keyless Entry Transmitter: Specifications REMOTE KEYLESS ENTRY TRANSMITTER RANGE Normal operation range is up to a distance of 3 to 7 meters (10 to 23 ft.) of the vehicle. Range may be better or worse depending on the environment around the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Component Tests and General Diagnostics Keyless Entry Transmitter: Component Tests and General Diagnostics REMOTE KEYLESS ENTRY TRANSMITTER Using special tool 9001, first test to ensure that the transmitter is functioning. Typical testing distance is 2.5 centimeters (1 inch) for Asian transmitters and 30.5 centimeters (12 inches) for all others. To test, position the transmitter as shown. Press any transmitter button, then test each button individually. The tool will beep if a radio signal strength that lights five or more LED's is detected. Repeat this test three times. If transmitter fails any of the test refer to the Diagnostic Procedures information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 14245 Keyless Entry Transmitter: Programming and Relearning STANDARD PROCEDURE - RKE TRANSMITTER PROGRAMING New Remote Keyless Entry (RKE) transmitters can be programed using the scan tool and the proper Diagnostic Procedures manual. The scan tool can provide confirmation that the PCI data bus is functional, and that all of the electronic modules are sending and receiving the proper messages on the PCI data bus. The following procedure can be used as long as one programmed transmitter is available: NOTE: When entering program mode using that programmed fob, ALL currently programmed fobs will be erased and they will have to be reprogrammed for the vehicle. If program mode is entered and no action is performed, the previously programmed fobs will continue to function. 1. Enter the vehicle and close all doors. 2. Fasten the seat belt (this will cancel the seat belt chime). Turn the ignition to the RUN position. 3. Press and hold the UNLOCK button on a programmed transmitter for 4 to 10 seconds. Within the 4 to 10 seconds with the UNLOCK button still depressed, press the PANIC button for one second. When a single chime is heard, release both buttons. The chime indicates the system is in program mode. 4. Press and release both the LOCK and UNLOCK buttons simultaneously on a fob to be programmed. A single chime will be heard, this indicates the fob has been recognized. 5. Press and release any button on the same fob. A single chime will be heard, this indicates the fob has been programmed. 6. Repeat steps 4 and 5 for up to a total of 4 fobs. 7. Turn the ignition OFF. 8. Turn the ignition ON or wait 60 seconds. The vehicle will remain in program mode for up to 60 seconds from when the original chime (step 3) was heard. After 60 seconds, all programmed transmitters will function normally. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Page 14246 Keyless Entry Transmitter: Service and Repair STANDARD PROCEDURE - RKE TRANSMITTER BATTERIES NOTE: Do not disturb the metal terminal near the batteries. Avoid touching the new batteries. Skin oils may cause battery deterioration. If batteries are touched, clean with rubbing alcohol. The Remote Keyless Entry (RKE) transmitter case snaps open and shut for battery access. To replace the RKE transmitter batteries: 1. Using a thin coin, gently pry at the notch in the center seam of the RKE transmitter case halves near the key ring until the two halves unsnap. Be careful not to damage the rubber gasket when separating the case halves. 2. Lift the back half of the transmitter case off of the RKE transmitter. 3. Remove the two batteries from the RKE transmitter. 4. Replace the two batteries with new 3V lithium 2016 cell. Install the batteries with the positive terminal up. Reference the "+ SIDE UP" on the inside of the bottom half of the transmitter case. 5. Align the two RKE transmitter case halves with each other, and squeeze them firmly and evenly together until they snap back into place. Test transmitter operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Description and Operation > Description Security Lamp/Indicator: Description and Operation Description DESCRIPTION A security indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional Vehicle Theft Security System (VTSS), this indicator is electronically disabled. This indicator is located in the lower right quadrant of the instrument cluster, between the speedometer and the coolant temperature gauge. The security indicator consists of a small round cutout in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The security indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Description and Operation > Description > Page 14251 Security Lamp/Indicator: Description and Operation Operation OPERATION The security indicator gives an indication to the vehicle operator when the Vehicle Theft Security System (VTSS) is arming or is armed. On vehicles equipped with the Sentry Key Immobilizer System (SKIS), the security indicator also gives an indication to the vehicle operator of the status of the SKIS. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming, hard wired inputs to the cluster from the various security system components, and electronic messages received by the cluster from the Sentry Key REmote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) over the Controller Area Network (CAN) data bus. The security indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will allow this indicator to operate whenever the instrument cluster receives a battery current input on the fused B(+) circuit. Therefore, the LED can be illuminated regardless of the ignition switch position. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. Depending upon the programmed condition the indicator can be illuminated solid, flashed at a slow rate (0.5 Hertz, 12.5 percent duty cycle), or flashed at a fast rate (1 Hertz, 50 percent duty cycle). The instrument cluster will turn ON the security indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the security indicator illuminates for about two seconds as a bulb test. The entire bulb test is a function of the SKREEM. VTSS Indication - During the 16 second VTSS arming function, the cluster will flash the security indicator ON and OFF repeatedly at a steady, fast rate to indicate that the VTSS is in the process of arming. Following successful VTSS arming, the cluster flashes the security indicator ON and OFF continuously at a slower rate to indicate that the VTSS is armed. The security indicator continues flashing at the slower rate until the VTSS is disarmed or triggered. If the VTSS has alarmed and rearmed, the cluster will flash the security indicator at a steady, slow rate for about 30 seconds after the VTSS is disarmed. - SKIS Indicator Lamp-On Message - Each time the cluster receives an electronic SKIS indicator lamp-ON message from the SKREEM, the security indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the SKREEM message. The indicator remains illuminated solid or continues to flash until the cluster receives a lamp-OFF message from the SKREEM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the SKREEM for 10 consecutive message cycles, the security indicator is illuminated by the instrument cluster. The indicator remains controlled and illuminated by the cluster until a valid lamp-ON or lamp-OFF message is received from the SKREEM. - Actuator Test - Each time the instrument cluster is put through the actuator test, the security indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The instrument cluster circuitry controls the security indicator whenever the ignition switch is in the OFF position and the VTSS is arming, armed, or alarming. Whenever the ignition switch is in the ON or START positions, the SKREEM performs a self-test to decide whether the SKIS is in good operating condition and whether a valid key is present in the ignition lock cylinder. The SKREEM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the cluster flashes the security indicator upon ignition ON, or turns ON the security indicator solid after the bulb test, it indicates that a SKIS malfunction has occurred or that the SKIS is ineffective. For proper diagnosis of the VTSS, the SKIS, the SKREEM, the EMIC, the CAN data bus or the electronic communication related to security indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Audio System - Cell Phone Induced Clicking From Speakers Cellular Phone: Technical Service Bulletins Audio System - Cell Phone Induced Clicking From Speakers NUMBER: 08-046-06 GROUP: Electrical DATE: October 25, 2006 SUBJECT: Cell Phone Induced Buzz Or Clicking-Like Sound In Radio Speakers OVERVIEW: This bulletin involves a discussion regarding cell phone generated signal interference with the vehicle radio system. MODELS: 2004 (AN) Dakota 2004 - 2007 (DR/DH/D1/DC) Ram Truck 2004 - 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2007 (KA) Nitro 2004 - 2007 (KJ) Liberty 2005 - 2007 (ND) Dakota 2004 - 2006 (TJ) Wrangler 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander SYMPTOM/CONDITION: A customer may experience a buzzing or clicking-like sound coming from the vehicle radio speaker(s). The sound may be heard when the radio is in AM or FM mode. The clicking-like sound may sound like Morse code. DISCUSSION: The hardware construction of certain cell phones may generate frequencies that can interfere with the vehicle radio system. These frequencies may result in buzzing and/or clicking-like sounds in the vehicle radio. GSM type cell phones are more prone to cause this possible interference condition, though other type cell phones may cause similar buzzing and/or clicking-like sounds. This condition can be easily corrected by instructing the customer to move their cell phone away from the immediate area around vehicle radio system (radio, radio amplifier, antenna, antenna lead). DO NOT replace any radio system component in an attempt to address this condition. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions Cellular Phone: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 14258 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 14259 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 14260 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 14261 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 14262 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 14263 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 14264 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 14265 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 14266 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 14267 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 14268 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 14269 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 14270 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 14271 Cellular Phone: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 14272 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 14273 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 14274 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 14275 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Description and Operation > Description Cellular Phone: Description and Operation Description DESCRIPTION NAVIGATION A optional navigation radio (RB4) is available on this vehicle. The navigation system allows the user to input addresses, points of interest or way points to plan a route to the desired location. The system will provide audible and visual prompts that will direct the user along the desired route. Any variances in the route will cause the navigation system to automatically recalculate the route. The Electronic Vehicle Information Center (EVIC) displays turn-by-turn directions to a programmed destination when Turn by Turn Navigation is enabled through Personal Settings. When enabled, the EVIC displays the name of the approaching road at the top of the screen, followed by an arrow to indicate the direction to turn the vehicle, and a count down to indicate the distance to the turn. TELECOMMUNICATIONS The hands-free cellular system on this vehicle uses Bluetooth(TM) technology to provide wireless communication between the operator's compatible cellular telephone and the vehicle's on-board receiver. The system uses voice recognition technology to control operation. The incoming voice is broadcast through the vehicle's radio speakers, automatically overriding any other audio signals on the front speakers when the hands-free system is in use. A microphone in the rearview mirror picks up vehicle occupant's voices. If a call is in progress when the ignition is switched off, the hands-free system will continue to operate for up to 45 seconds as part of the Accessory Relay Delay function. Thereafter, the call can continue on the hand-held telephone. The system will communicate with a telephone that is anywhere within the vehicle. However, covering the hand held phone or the hands-free phone module with a metal object may block the signal. The system will recognize up to seven telephones, each of which is given a spoken identification by the user during the setup process. The system includes Spanish and French voice recognition in addition to English. Two buttons on the rearview mirror, identified with ISO icons, control the system: A "phone" button turns the system on and off; a "voice recognition" (or voice command) button prompts the hands-free system to listen for a voice command. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Description and Operation > Description > Page 14278 Cellular Phone: Description and Operation Operation OPERATION Navigation The optional navigation radio system receives GPS signals from up to eight satellites to display the position and direction of the vehicle. Map information is supplied through a DVD-ROM. An electronic gyro-sensor and the vehicle's speed sensor enable the system to display the present vehicle position even in locations where GPS signals may be blocked. When a destination is selected, the navigation system uses information from the map to quickly calculate a route. As the vehicle is driven along the chosen route, the operator is guided with pictorial displays and voice prompts. TELECOMMUNICATION Two buttons on the rearview mirror, identified with ISO icons, control the system: A "phone" button turns the system on and off; a "voice recognition" (or voice command) button prompts the hands-free system to listen for a voice command. The system includes the following features: - Phone book - Stores telephone numbers for later recall by name or other verbal identification, called a voice tag, and memory location. - Four memory locations - Home, Work, Cellular and Pager. A maximum of 32 unique names or voice tags may be stored at the same time, with a different number in each of the four memory locations. - Voice tag dialing - Dials the number associated with a voice tag and memory location. - Digit dialing - Dials the telephone number by recognizing the names of the digits as they are spoken. - Receiving calls - A voice prompt notifies the user of an incoming call. A voice response accepts or rejects the call without manual intervention. - Privacy Mode - Switches the call to the handheld telephone and the hands-free system and back again using the "voice recognition" (or "voice command") button and a voice command, if desired. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Description and Operation > Page 14279 Cellular Phone: Testing and Inspection TELECOMMUNICATION Any diagnosis of the Telecommunication system should begin with the use of scan tool. For information on the use of the scan tool. For complete circuit diagrams, refer to the appropriate wiring information. WARNING: On vehicles equipped with airbags, refer to electrical, restraints before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Description and Operation > Page 14280 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Description and Operation > Page 14281 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Service and Repair > Removal Cellular Phone: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel right side end cap. 3. Remove the mounting fasteners. 4. Disconnect the electrical harness connector and remove module. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Service and Repair > Removal > Page 14284 Cellular Phone: Service and Repair Installation INSTALLATION 1. Connect the electrical harness connector and position module. 2. Install and tighten the mounting fasteners. 3. Install the instrument panel right side end cap. 4. Connect battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions Collision Avoidance and Parking Assist Systems: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14289 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14290 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14291 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14292 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14293 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14294 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14295 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14296 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14297 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14298 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14299 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14300 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14301 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14302 Collision Avoidance and Parking Assist Systems: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14303 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14304 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14305 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14306 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 14311 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 14312 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 14313 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 14314 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 14315 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 14316 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 14317 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 14318 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 14319 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 14320 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 14321 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 14322 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 14323 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 14324 Driver/Vehicle Information Display: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 14325 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 14326 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 14327 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 14328 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 14329 Driver/Vehicle Information Display: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-49-02 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 14330 Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Description Driver/Vehicle Information Display: Description and Operation Description DESCRIPTION NOTE: The Electronic Vehicle Information Center (EVIC) module is sometimes referred to as Electronic Overhead Module (EOM) for the purposes of scan tool and diagnostic information naming. Please treat the EVIC and EOM as one and the same when diagnosing the vehicle. The Electronic Vehicle Information Center (EVIC) is located in the overhead console and consists of the following components: - HomeLink(R) transceiver (3) - if equipped - Vacuum-Fluorescent Display (VFD) (6) - Push button function switches (1, 2, 3, 4 and 5) - Replaceable light bulbs to illuminate the push button function switches This system conveniently allows the driver to select a variety of useful information by pressing the function buttons. The EVIC displays information related to the following: - System Status - Vehicle information warning message displays - Tire Pressure Monitor System - If Equipped - Personal Settings (customer programmable features) - Compass display - Outside temperature display - Trip computer functions The EVIC system is comprised of several different components. Those components are: - Instrument Cluster (also known as Cab Compartment Node (CCN)) - Ambient Temperature Sensor - EVIC Module - Controller Area Network (CAN) Data Bus circuit The individual components of the EVIC module are not serviced separately and if damaged or inoperative, must be replaced as a unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Description > Page 14333 Driver/Vehicle Information Display: Description and Operation Operation OPERATION The Electronic Vehicle Information Center (EVIC) uses both non-switched and ignition switched sources of battery current so that some of its features remain operational at any time, while others may only operate with the ignition switch in the On position. When the ignition switch is turned to the On position, the EVIC display will return to the last function being displayed before the ignition was turned to the Off position. The EVIC system is comprised of several different components that communicate over the Controller Area Network (CAN) Data Bus. If the system is inoperative a scan tool and the appropriate diagnostic information must be used to diagnose the system. The EVIC push buttons are used to operate the different functions of the EVIC system. Pressing and releasing the MENU button (1) will change the mode displayed to one of the Personal Settings. The STEP button (2) is used to make a selection from the Personal Settings displayed at that time. Pressing and releasing the C/T (compass/temperature) button (5) will cause the EVIC to return to the compass/temperature/trip computer display mode from any other mode. From the compass/temperature/trip computer display mode the STEP button (2) is used to scroll through and make selections in the Trip Functions. Pressing and releasing the RESET button (4) resets the trip computer screen displayed at that time. EVIC DISPLAY MODES SYSTEM STATUS MODE Displays warnings and user interaction messages. Critical text warnings will be displayed until the failure is corrected. Non-critical text warnings will be displayed for 60 seconds. The driver can scroll to view multiple messages by using the STEP button. When the appropriate conditions exist, the EVIC displays the following messages: - TURN SIGNALS ON (with a continuous warning chime) - RKE BATTERY LOW (with a single chime) - PERSONAL SETTINGS NOT AVAILABLE - Vehicle Not in Park - LEFT/RIGHT FRONT DOOR AJAR (one or more, with a single chime if speed is above 1 mph) - LEFT/RIGHT REAR DOOR AJAR (one or more, with a single chime if speed is above 1 mph) - DOOR(S) AJAR (with a single chime if vehicle is in motion) - LOW WASHER FLUID (with a single chime) - SERVICE PARK ASSIST SYSTEM (with a single chime) - OIL CHANGE REQUIRED (with single chime) - LEFT FRONT TURN LAMP OUT - RIGHT FRONT TURN LAMP OUT - LEFT REAR TURN LAMP OUT - RIGHT REAR TURN LAMP OUT - SERVICE PARK ASSIST SYSTEM - CATALYST FULL SEE OWNER MANUAL - CATALYST STAT lllll 99% - CATALYST FULL SERVICE REQUIRED - SERVICE AIR FILTER - SERVICE CCV FILTER - COOLANT LOW - ESP SYSTEM DEACTIVATED Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Description > Page 14334 - AUTO HIGH BEAMS ON - AUTO HIGH BEAMS OFF PERSONAL SETTINGS MODE (CUSTOMER PROGRAMMABLE FEATURES) Allows the driver to set and recall features when the transmission is in Park by pressing and releasing the MENU button until Personal Settings is displayed in the EVIC. If the transmission is not in PARK the EVIC will display NOT AVAILABLE and VEHICLE NOT IN PARK. The following personal settings can be set and recalled by pressing the STEP button: - "LANGUAGE" - When in this display you may select one of three languages for all display nomenclature, including the trip functions. Press the RESET button while in this display to select English, Espanol, or Francais. Then, as you continue, the information will display in the selected language. - "AUTO DOOR LOCKS > YES" - When ON is selected, all doors will lock automatically when the vehicle reaches a speed of 15 mph (24 km/h). To make your selection, press and release the RESET button until "ON" or "OFF" appears. - "AUTO UNLOCK ON EXIT > YES" - When ON is selected, all doors will unlock when the vehicle is stopped and the transmission is in the P (Park) or N (Neutral) position and the driver's door is opened. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - "RKE UNLOCK DRV DR 1st" - When DRV DR 1st is selected, only the driver's door will unlock on the first press of the remote keyless entry unlock button. When Driver Door 1st Press is selected, you must press of the remote keyless entry unlock button twice to unlock the passenger's doors. To make your selection, press and release the RESET button until "DRV DR 1st " appears. - "RKE UNLOCK ALL DR 1ST" - When All ALL DR 1ST is selected, all of the doors will unlock on the first press of the remote keyless entry unlock button. To make your selection, press and release the RESET button until "All DR 1st" appears. - "SOUND HORN W/LOCK > YES" - When ON is selected, a short horn sound will occur when the remote keyless entry "Lock" button is pressed. This feature may be selected with or without the flash lights on lock/unlock feature. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - "FLASH LIGHTS w/LOCK > YES" - When ON is selected, the front and rear turn signals will flash when the doors are locked or unlocked with the remote keyless entry transmitter. This feature may be selected with or without the sound horn on lock feature selected. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - "HEAD LAMP OFF DELAY > 0 SEC" - When this feature is selected, the driver can choose to have the headlights remain on for 0, 30, 60, or 90 seconds when exiting the vehicle. To make your selection, press and release the RESET button until "0," "30," "60," or "90" appears. - "KEY OFF POWER DELAY > OFF" - When this feature is selected, the power window switches, radio, hands-free system (if equipped), DVD video system (if equipped) and power outlets will remain active for up to 60 minutes after the ignition switch is turned off. Opening a vehicle door will cancel this feature. To make your selection, press and release the RESET button until "Off," "45 sec.," "5 min.," "10 min." appears. - "ILLUMINATED APRCH > OFF" - When this feature is selected, the headlights will activate and remain on for up to 90 seconds when the doors are unlocked with the remote keyless entry transmitter. To make your selection, press and release the RESET button until "OFF," "30 sec.," "60 sec.," or "90 sec." appears. - "UNIT IN > US/METRIC" - The EVIC, odometer can be changed between English and Metric units of measure. To make your selection, press and release the RESET button until "US" or "METRIC" appears. - "COMPASS VARIANCE > 1" - Press the RESET button to change the compass variance setting. - "COMPASS CALIBRATE > YES" - Press the RESET button to calibrate the compass. COMPASS/TEMPERATURE/TRIP COMPUTER MODE This display provides the outside temperature, one of the eight compass headings to indicate the direction the vehicle is facing, and vehicle trip information. The compass and temperature display is the normal display. When the C/T button is pressed the EVIC returns to the compass/temperature display from all other functions. The trip computer function will be displayed if the STEP button is pressed from the Compass/Temperature display mode. The trip computer displays the following information: - TRIP - Shows the total distance traveled since the last reset. To reset the TRIP function, press and hold the RESET button. - ELAPSED TIME - Shows the total elapsed time of travel since the last reset. Elapsed time will increment when the ignition switch is in the ON/RUN or START positions. - UNIT IN US/METRIC - Press the RESET button to toggle between US and METRIC. - AVG. MPG - Shows the average fuel economy since the last reset. When the fuel economy is reset, the display will show dashes for two seconds. Then the history information will be erased, and the averaging will continue from the last fuel average reading before the reset. (Example: If your Electronic Vehicle Information Center (EVIC) displays 18 AVG. MPG and the RESET button is pressed, the previous averaging history will be erased and the display will return to the 18 AVG. MPG, not to 0 AVG. MPG). The display may take several miles for the value to change dependent upon driving habits. - MI TO EMPTY (Distance To Empty) - Shows the estimated distance that can be traveled with the fuel remaining in the tank. This estimated distance is determined by a weighted average of fuel economy, according to the current fuel tank level. Distance MI TO EMPTY cannot be reset through the RESET button. When the DTE value is less than 30 miles (48 km) estimated driving distance, the DTE display will change to a text display of "LOW FUEL." This display will continue until the vehicle runs out of fuel. Adding a significant amount of fuel to the vehicle will turn off the "LOW FUEL" text and a new DTE value will display. UNIVERSAL GARAGE DOOR (HOMELINK(R)) TRANSCEIVER Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Description > Page 14335 The EVIC features a driver-interactive display which includes HomeLink(R) system messages. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Page 14336 Driver/Vehicle Information Display: Testing and Inspection ELECTRONIC VEHICLE INFORMATION CENTER The Electronic Vehicle Information Center (EVIC) data is obtained from several components on the Controller Area Network (CAN) Data Bus circuit. The EVIC will not function properly if the bus messages from any of these components is not received. If no EVIC data is displayed, check the CAN Data Bus circuit communications, the Instrument Cluster (also known as Cab Compartment Node (CCN)) functions and the Totally Integrated Power Module (TIPM). If the problem with the EVIC is an inaccurate or scrambled display, refer to SELF- DIAGNOSTIC TEST. If the problem with the EVIC is incorrect Vacuum Fluorescent Display (VFD) dimming levels, use a scan tool and the proper Diagnostic Procedures Information to test for the correct dimming message inputs being received from the CCN or TIPM over the CAN data bus circuit. If the problem is a no-display condition, use the following procedure. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the overhead console from the headliner. 2. Inspect the Ignition Off Draw (IOD) fuse in the TIPM. If the IOD fuse is OK and in place, go to STEP 3. If not OK, repair the open IOD fuse circuit as required. 3. Check for battery voltage at the overhead console electrical connector. If OK, go to STEP 4. If not OK, Check for battery voltage at the appropriate B(+) fuse in the TIPM, repair the open fused B(+) circuit as required. 4. Turn the ignition switch to the On position. Check the fused ignition switch output circuit(s) at the overhead console electrical connector. If OK, go to STEP 5. If not OK, repair the open or shorted circuit as required. 5. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Check for continuity between the ground circuit cavity of the overhead console electrical connector and a good ground. There should be continuity. If OK, refer to SELF- DIAGNOSTIC TEST for further diagnosis of the EVIC module and the CAN data bus circuit. If not OK, repair the open ground circuit as required. SELF- DIAGNOSTIC TEST NOTE: The EVIC self - test can also be performed using a scan tool. Navigate to the Auto Self Test screen under System Tests of the scan tool and initiate the EVIC self - test. A self-diagnostic test is used to determine that the EVIC is operating properly electrically. Initiate the self-diagnostic test as follows: 1. With the ignition switch in the Off position, simultaneously depress and hold the STEP and RESET buttons while rotating the ignition switch to the Run/On position. 2. Continue to hold both buttons depressed until the EVIC enters the display segment test. In this test, all of the Vacuum Fluorescent Display (VFD) segments are lighted while the EVIC performs the following checks: - Non-Volatile Memory Status (NVM) - RAM Status - ROM Status - ASIC Communication Status - Compass Status - DC Status - CAN Data Bus Communications Status NOTE: If the EVIC module is equipped with the Universal Transmitter (also known as HomeLink(R)), the module also checks "HomeLink(R) Communication Test Status". 3. Following completion of these tests, the EVIC will display one of two messages: "Self Test: FAIL" or "Self Test: PASS." In addition to the FAIL/PASS message the EVIC will display the current software version (SW V xx.xx.xxx) below the FAIL/PASS info. Press the RESET or STEP button to exit and enter normal mode. Respond to these test results as follows: - If no test result message is displayed, but EVIC operation is still improper, the use of a scan tool and the proper Diagnostic Procedures Information are required for further diagnosis. - If the "Self Test: FAIL" message is displayed, the EVIC is inoperative and must be replaced. - If the "Self Test: PASS" message is displayed, the EVIC is OK, no faults are present. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Page 14337 - If any VFD segment does not light during the display segment test, the EVIC is inoperative and must be replaced. If the first seven tests pass, the EVIC shall verify that all the required CAN bus messages are present on the CAN bus. If all required messages are present on the CAN bus, the EVIC will automatically return to normal operation after sixty seconds. The EVIC can also be returned to normal operation any time during the test by pressing the STEP, C/T, RESET or US/M buttons. NOTE: Pressing the STEP or RESET buttons during any portion of the EVIC Self - Diagnostic Test Procedure will cause the EVIC to exit diagnostics and return to compass/temperature mode. NOTE: If the compass functions, but accuracy is suspect, it may be necessary to perform a variance adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. NOTE: If the compass reading has blanked out, and only "CAL" appears in the display, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle. Check for stored Diagnostic Trouble Codes (DTCs) and follow the proper Diagnostic Procedures Information as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Adjustments > Manual Compass Calibration Driver/Vehicle Information Display: Adjustments Manual Compass Calibration MANUAL COMPASS CALIBRATION CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the overhead console. Do not use magnetic tools when servicing the overhead console. NOTE: Whenever the compass is calibrated manually, the variance number must also be reset. The electronic compass unit features a self-calibrating design, which simplifies the calibration procedure. This feature automatically updates the compass calibration while the vehicle is being driven. This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use. If the compass readings appear to be erratic or the Electronic Vehicle Information Center (EVIC) displays "CAL", perform the following manual calibration procedure. Also, any time EVIC service replacement components are installed, they must be calibrated using this procedure. Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. Calibrate the compass manually as follows: 1. Turn the ignition switch to the On/Run position. Press and release the MENU push button (1) until "Personal Settings" is displayed. 2. Press the STEP push button (4) until "Calibrate Compass YES" is displayed. 3. Momentarily depress and release the RESET push button (2) to initiate the calibration procedure. The message "CAL will appear in the Compass/Temperature display. 4. Slowly drive the vehicle on a level surface, away from large metal objects and power lines, through one or two complete circles not exceeding 8 km/h (5 mph). The "CAL" message will disappear from the display to indicate that the compass is now calibrated. NOTE: A blank compass display indicates that vehicle degaussing (demagnetizing) may be necessary. NOTE: If the "CAL" message remains in the display, either there is excessive magnetism near the compass, or the EVIC is inoperative. Attempt the calibration procedure at least one more time before performing EVIC diagnosis. NOTE: If the wrong direction is still indicated in the compass display, the area selected for calibration may be too close to a strong magnetic field. Repeat the manual calibration procedure in another location. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Adjustments > Manual Compass Calibration > Page 14340 Driver/Vehicle Information Display: Adjustments Compass Variance Adjustment COMPASS VARIANCE ADJUSTMENT Compass variance, also known as magnetic declination, is the difference in angle between magnetic north and true geographic north. In some geographic locations, the difference between magnetic and geographic north is great enough to cause the compass to give false readings. If this problem occurs, the compass variance must be set. NOTE: If the vehicle is taken on long trips into a new variance zone the compass function may be effected. Compass variance may need to be adjusted to the new zone number to function properly. NOTE: The default for the compass variance from the factory is 8. To set the compass variance: 1. Using the Variance Settings Map, find your geographic location and note the zone number. 2. Turn the ignition switch to the On/Run position. Press and release the MENU push button (1) until "Personal Settings" is displayed. 3. Press the STEP push button (4) until "Compass Variance" is displayed. 4. Momentarily depress and release the RESET push button (2) to toggle through the zone numbers (1-15), until the zone number for your geographic location appears in the display. 5. Momentarily depress and release the C/T push button (5) to enter the displayed zone number into the compass unit memory. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Adjustments > Manual Compass Calibration > Page 14341 6. Confirm that the correct directions are now indicated by the compass. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures Driver/Vehicle Information Display: Procedures COMPASS DEMAGNETIZING A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the overhead console forward mounting screw and the roof panel above the overhead console. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 millimeters (0.25 inch) beyond the tip of the probe. To demagnetize the roof panel and the overhead console forward mounting screw, proceed as follows: 1. Be certain that the ignition switch is in the Off position, before you begin the demagnetizing procedure. 2. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 3. Slowly approach the head of the overhead console forward mounting screw with the degaussing tool connected. 4. Contact the head of the screw with the plastic coated tip of the degaussing tool for about two seconds. 5. With the degaussing tool still energized, slowly back it away from the screw. When the tip of the tool is at least 61 centimeters (2 feet) from the screw head, disconnect the tool. To demagnetize the roof panel proceed as follows: 6. Place a piece of paper approximately 22 by 28 centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header. The purpose of the paper is to protect the roof panel from scratches, and to define the area to be demagnetized. 7. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 14344 8. Slowly approach the center line of the roof panel at the windshield header, with the degaussing tool connected. 9. Contact the roof panel with the plastic coated tip of the degaussing tool. Be sure that the template is in place to avoid scratching the roof panel. Using a slow, back-and-forth sweeping motion, and allowing 13 millimeters (0.50 inch) between passes, move the tool at least 11 centimeters (4 inches) to each side of the roof center line, and 28 centimeters (11 inches) back from the windshield header. 10. With the degaussing tool still energized, slowly back it away from the roof panel. When the tip of the tool is at least 61 centimeters (2 feet) from the roof panel, disconnect the tool. 11. Calibrate the compass and adjust the compass variance. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 14345 Driver/Vehicle Information Display: Removal and Replacement Electronic Vehicle Information Center ELECTRONIC VEHICLE INFORMATION CENTER 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console (3) from the headliner. 3. Remove the screws (2) that secure the Electronic Vehicle Information Center (EVIC) (3) to the overhead console housing (1). 4. Remove the EVIC (3) from the overhead console housing (1). Bulb - EVIC Control BULB - EVIC CONTROL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: There are provisions for up to four bulb/bulb holder units on the Electronic Vehicle Information Center (EVIC) circuit board. The two outboard bulbs illuminate the EVIC push buttons, while the two center bulbs illuminate the optional universal transmitter push buttons. Therefore, the center bulb locations are only populated on vehicles equipped with the optional universal transmitter. 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console (1) from the headliner. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 14346 3. Use a small thin-bladed screwdriver to rotate the bulb holder (3) counterclockwise about 30 degrees to unlock it from the keyed opening in the Electronic Vehicle Information Center (EVIC) unit (2) circuit board. 4. Pull the bulb holder and bulb straight out of the circuit board. Electronic Vehicle Information Center ELECTRONIC VEHICLE INFORMATION CENTER NOTE: If a new Electronic Vehicle Information Center (EVIC) has been installed, the compass will have to be calibrated and the variance set. 1. Position the EVIC (3) onto the overhead console housing (1). 2. Install the screws (2) that secure the EVIC (3) to the overhead console housing (1). Tighten the screws to 2 Nm (20 in. lbs.). 3. Install the overhead console (1) onto the headliner. 4. Reconnect the battery negative cable. Bulb - EVIC Control BULB - EVIC CONTROL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: There are provisions for up to four bulb/bulb holder units on the Electronic Vehicle Information Center (EVIC) circuit board. The two outboard bulbs illuminate the EVIC push buttons, while the two center bulbs illuminate the optional universal transmitter push buttons. Therefore, the center bulb locations are only populated on vehicles equipped with the optional universal transmitter. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 14347 1. Align the bulb holder and bulb (3) with the keyed opening in the circuit board of the Electronic Vehicle Information Center (EVIC) (2). 2. Insert the bulb holder and bulb straight into the circuit board until the bulb holder is firmly seated. 3. Using a small thin-bladed screwdriver, rotate the bulb holder clockwise about 30 degrees on the circuit board to lock it into place. 4. Reinstall the overhead console (1) onto the headliner. 5. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Locations Television / Monitor: Locations Component ID: 194 Component : MEDIA SYSTEM-MONITOR/DVD Connector: Name : MEDIA SYSTEM-MONITOR/DVD Color : BLACK # of pins : 12 Pin Description Circuit 1 RIGHT AUDIO AUX X510 20DG/LB 2 SDARS AUDIO RETURN X916 20GY/OR 3 LEFT AUDIO AUX X521 20GY/LB 4-5-6 FUSED B(+) A114 18GY/RD 7 LEFT AUDIO AUX X511 20GY/LG 8 AUX AUDIO RETURN X910 20GY/DG 9 RIGHT AUDIO AUX X522 20GY/DB 10 CAN B BUS (+) D55 20WT/OR 11 CAN B BUS (-) D54 20WT 12 GROUND Z957 18BK Component Location - 54 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Locations > Page 14352 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Locations > Page 14353 Television / Monitor: Diagrams Component ID: 194 Component : MEDIA SYSTEM-MONITOR/DVD Connector: Name : MEDIA SYSTEM-MONITOR/DVD Color : BLACK # of pins : 12 Pin Description Circuit 1 RIGHT AUDIO AUX X510 20DG/LB 2 SDARS AUDIO RETURN X916 20GY/OR 3 LEFT AUDIO AUX X521 20GY/LB 4-5-6 FUSED B(+) A114 18GY/RD 7 LEFT AUDIO AUX X511 20GY/LG 8 AUX AUDIO RETURN X910 20GY/DG 9 RIGHT AUDIO AUX X522 20GY/DB 10 CAN B BUS (+) D55 20WT/OR 11 CAN B BUS (-) D54 20WT 12 GROUND Z957 18BK Component Location - 54 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Locations > Page 14354 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Description and Operation > Description Television / Monitor: Description and Operation Description DESCRIPTION The video entertainment system, consist of: - Battery powered remote control - Two headsets - Video monitor/DVD Player located on the headliner. In addition to video DVDs, the system will play audio DVDs, audio CDs, MP3 audio disc, and video CDs. There are plug-in jacks on the monitor/player to show video directly from a video camera, connect video games for display on the screen, and play music directly from a MP3 player. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Description and Operation > Description > Page 14357 Television / Monitor: Description and Operation Operation OPERATION A seven inch (diagonal measurement) liquid crystal display (LCD) screen supports both 3 X 4 and 6 X 9 video formats. The hinged screen latches in the closed position and swings down for viewing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Service and Repair > Removal Television / Monitor: Service and Repair Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the two mounting fasteners. 3. Using a trim stick, press the retaining clip at the rear of the monitor (3). Move the monitor from side to side to release from headliner (2). 4. Disconnect electrical harness connector (1) and remove monitor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Service and Repair > Removal > Page 14360 Television / Monitor: Service and Repair Installation INSTALLATION 1. Connect electrical harness connector (1) to monitor (3). 2. Position monitor and press into place. 3. Install and tighten mounting fasteners. 4. Connect battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Description and Operation > Description Garage Door Opener Transmitter: Description and Operation Description DESCRIPTION NOTE: The Compass Mini-Trip Computer (CMTC) and Electronic Vehicle Information Center (EVIC) modules are sometimes referred to as Electronic Overhead Modules (EOM) for the purposes of scan tool and diagnostic information naming. Please treat the CMTC, EVIC and EOM as one and the same when diagnosing the vehicle. NOTE: Overhead console with Compass Mini-Trip Computer (CMTC) shown. Overhead console with Electronic Vehicle Information Center (EVIC) is similar. The HomeLink(R) transceiver is integral to the CMTC or EVIC modules. The only visible component of the HomeLink(R) transceiver are the three push buttons (3). The buttons are marked with one, two or three dots, respectively, for identification of each channel. Each of the three HomeLink(R) transceiver push buttons controls an independent radio transmitter channel. Each of these three channels can be trained to transmit a different radio frequency signal for the remote operation of garage door openers, motorized gate openers, home or office lighting, security systems or just about any other device that can be equipped with a radio receiver in the 286 to 399 Megahertz (MHz) frequency range for remote operation. The HomeLink(R) transceiver is capable of operating systems using either rolling code or non-rolling code technology. The HomeLink(R) transceiver cannot be repaired, and is available for service only as part of the CMTC or EVIC modules. This unit includes the push button switches for both the HomeLink(R) transceiver and CMTC or EVIC, The Vacuum-Fluorescent Display (VFD) and the plastic module case. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Description and Operation > Description > Page 14365 Garage Door Opener Transmitter: Description and Operation Operation OPERATION The HomeLink(R) transceiver receives battery feed through the Ignition Off Draw (IOD) fuse circuit of the vehicle. It operates on a non-switched source of battery current so the unit will remain functional, regardless of the ignition switch position. It can learn and store three separate transmitter radio frequency codes to operate garage door openers, security gates and security lighting. The Compass Mini-Trip Computer (CMTC) or Electronic Vehicle Information Center (EVIC) display provides visual feedback to the driver, showing which transmitter button is pressed. The system will not send operating signals if the vehicle theft security alarm is armed. This prevents a perpetrator from breaking into a vehicle parked outside a home and using the HomeLink(R) transceiver system to enter the home. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Component Tests and General Diagnostics Garage Door Opener Transmitter: Component Tests and General Diagnostics HOMELINK(R) TRANSCEIVER RADIO FREQUENCY DETECTOR #9001 If the HomeLink(R) transceiver is inoperative, but the Compass Mini-Trip Computer (CMTC) or Electronic Vehicle Information Center (EVIC) Vacuum-Fluorescent Display (VFD) is operating normally. Retrain the HomeLink(R) transceiver with a known good hand held transmitter as instructed and test the HomeLink(R) transceiver operation again. If the unit is still inoperative, test it with the Radio Frequency Detector special tool 9001 as described below: 1. Turn the Radio Frequency (RF) Detector ON. A "chirp" will sound and the green power Light Emitting Diode (LED) indicator will light. If the green LED does not light, replace the battery. 2. Hold the RF detector within one inch of the TRAINED HomeLink(R) transceiver and press any of the transceiver buttons. 3. The red signal detection LEDs will light and the tool will beep if a radio signal is detected. Repeat this test for each button. If any button is inoperative, replace the CMTC or EVIC modules. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 14368 Garage Door Opener Transmitter: Programming and Relearning Programming Homelink(R) Transceiver Codes PROGRAMMING HOMELINK(R) TRANSCEIVER CODES WARNING: Vehicle exhaust contains carbon monoxide, a dangerous gas. Do not run the vehicle's exhaust while training the transceiver. Exhaust gas can cause serious injury or death. WARNING: Your motorized door or gate may open and close while you are training the HomeLink(R) transceiver if the vehicle is in range of the motorized device. Do not train the HomeLink(R) transceiver if people or pets are in the path of the door or gate. A moving door or gate can cause serious injury or death to people and pets or damage to objects. NOTE: When programming a garage door opener, it is advised to park outside the garage. It is also recommended that a new battery be placed in the hand-held transmitter of the device being programmed to the HomeLink(R) transceiver for quicker training and accurate transmission of the radio-frequency signal. NOTE: If programing the HomeLink(R) transceiver is unsuccessful using the following procedure, refer to the Owner's Manual. Programming Common HomeLink(R) Transceiver Codes (Compass Mini - Trip Computer (CMTC) Equipped Models) - Press and hold the two outer HomeLink(R) transceiver buttons, and release only when the indicator light begins to flash (after 20 seconds). Do not hold the buttons for longer than 30 seconds and do not repeat step one to program a second and/or third hand-held transmitter to the remaining two HomeLink(R) transceiver buttons. - Position the end of your hand-held transmitter 3-8 cm (1-3 inches) away from the HomeLink(R) transceiver buttons while keeping the indicator light in view. - Simultaneously press and hold both the HomeLink(R) transceiver button that you want to train and the hand-held transmitter button. Do not release the buttons until step 4 has been completed. NOTE: Some gate operators and garage door openers may require you to replace this Programming Step 3 with procedures noted in the "Gate Operator/Canadian Programming". - The HomeLink(R) transceiver indicator light will flash slowly and then rapidly after HomeLink(R) successfully receives the frequency signal from the hand-held transmitter. Release both buttons after the indicator light changes from the slow to rapid flash. - Press and hold the just trained HomeLink(R) transceiver button and observe the indicator light. If the indicator light stays on constantly, programming is complete and your device should activate when the button is pressed and released. NOTE: To program the remaining two buttons, begin with "Programming" step 2. Do not repeat step 1. If the indicator light blinks rapidly for two seconds and then turns to a constant light, continue with "Programming" steps 6-8 to complete the programming of a rolling code equipped device (most commonly a garage door opener). - At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. - Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.) NOTE: There are 30 seconds in which to initiate step 8. - Return to the vehicle and firmly press, hold for two seconds and release the programmed HomeLink(R) transceiver button. Repeat the "press/hold/release" sequence a second time, and, depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the programming. The HomeLink(R) transceiver should now activate your rolling code equipped device. NOTE: To program the remaining two HomeLink(R) transceiver buttons, begin with "Programming" step 2. Do not repeat step 1. Programming Common HomeLink(R) Transceiver Codes (Electronic Vehicle Information Center (EVIC) Equipped Models) - Press and hold the two outer HomeLink(R) transceiver buttons, the EVIC will display "CLEARING CHANNELS" , do not release the buttons until "CHANNELS CLEARED" is displayed on the EVIC (after approximately 20 seconds). Do not hold the buttons for longer than 30 seconds and do not repeat step one to program a second and/or third hand-held transmitter to the remaining two HomeLink(R) transceiver buttons. The HomeLink(R) transceiver is now in the train (or learning) mode - Position the end of your hand-held transmitter 3-8 cm (1-3 inches) away from the HomeLink(R) transceiver buttons while keeping the EVIC display in view. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 14369 - Simultaneously press and hold both the HomeLink(R) transceiver button that you want to train and the hand-held transmitter button. Do not release the buttons until step 4 has been completed. The EVIC will display "CHANNEL X TRAINING", once the HomeLink(R) transceiver is programmed the EVIC will display "CHANNEL X TRAINED". X refers to the desired channel being trained (1,2 or 3). NOTE: Some gate operators and garage door openers may require you to replace this Programming Step 3 with procedures noted in the "Gate Operator/Canadian Programming" section. - Once "CHANNEL X TRAINED" is displayed on the EVIC, release both buttons. Programming is now complete. When the HomeLink(R) transceiver button is subsequently pressed, "CHANNEL X TRANSMIT" is displayed on the EVIC and your device should be activated, (garage door should open). NOTE: To program the remaining two buttons, begin with "Programming" step 2. Do not repeat step 1. If the EVIC display shows "CHANNEL X TRANSMIT" (where X is channel 1,2 or 3) but your device does not activate, the device may be equipped with a "rolling code" system. Continue with the following steps five through seven to complete the programming of a rolling code equipped device (most commonly a garage door opener manufactured after 1995). The assistance of a second person may make the following programming steps quicker and easier. - At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. - Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.) NOTE: There are 30 seconds in which to initiate step 8. - Return to the vehicle and firmly press, hold for two seconds and release the programmed HomeLink(R) transceiver button. Repeat the "press/hold/release" sequence a second time, and, depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the programming. The HomeLink(R) transceiver should now activate your rolling code equipped device. NOTE: To program the remaining two HomeLink(R) transceiver buttons, begin with "Programming" step 2. Do not repeat step 1. Canadian Programming/Gate Programming Canadian radio-frequency laws require transmitter signals to "time-out" (or quit) after several seconds of transmission which may not be long enough for the HomeLink(R) transceiver to pick up the signal during programming. Similar to this Canadian law, some U.S. gate operators are designed to "time-out" in the same manner. If you live in Canada or you are having difficulties programming a gate operator by using the "Programming" procedures (regardless of where you live), replace "Programming Common HomeLink(R) Transceiver Codes" step 3 with the following: NOTE: When programming a garage door opener or gate operator, it is advised to unplug the device or move the vehicle out of range during the "cycling" process to prevent possible overheating. - 3. Continue to press and hold the HomeLink(R) transceiver button while you press and release every two seconds ("cycle") your hand-held transmitter until the frequency signal has successfully been accepted. (On CMTC equipped vehicles, the indicator light will flash slowly and then rapidly.) (On EVIC equipped vehicles, the EVIC will display "CHANNEL X TRAINING" and then "CHANNEL X TRAINED".) Proceed with "Programming" step 4 to complete. Reprogramming Homelink(R) Transceiver Codes REPROGRAMMING HOMELINK(R) TRANSCEIVER CODES WARNING: Vehicle exhaust contains carbon monoxide, a dangerous gas. Do not run the vehicle's exhaust while training the HomeLink(R) transceiver. Exhaust gas can cause serious injury or death. WARNING: Your motorized door or gate may open and close while you are training the HomeLink(R) transceiver if the vehicle is in range of the motorized device. Do not train the HomeLink(R) transceiver if people or pets are in the path of the door or gate. A moving door or gate can cause serious injury or death to people and pets or damage to objects. NOTE: If programing the HomeLink(R) transceiver is unsuccessful using the following procedure, refer to the Owner's Manual. Reprogramming Basic HomeLink(R) Transceiver Codes (Compass Mini - Trip Computer (CMTC) Equipped vehicles) To program a device to the HomeLink(R) transceiver using a button previously trained, follow these steps: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 14370 - Press and hold the desired HomeLink(R) transceiver button. DO NOT release the button. The indicator light will begin to flash after 20 seconds. Without releasing the HomeLink(R) transceiver button, proceed to step 2. - Position the end of your hand-held transmitter 3-8 cm (1-3 inches) away from the HomeLink(R) transceiver button while keeping the indicator light in view. - Simultaneously press and hold both the HomeLink(R) transceiver button that you want to train and the hand-held transmitter buttons. Do not release the buttons until step 4 has been completed. NOTE: Some gate operators and garage door openers may require you to replace this Reprogramming Step 3 with procedures noted in the "Gate Operator/Canadian Programming" section. - The HomeLink(R) transceiver indicator light will flash slowly and then rapidly after it successfully receives the frequency signal from the hand-held transmitter. Release both buttons after the indicator light changes from the slow to the rapid flash. - Press and hold the just trained HomeLink(R) transceiver button and observe the indicator light. If the indicator light stays on constantly, reprogramming is complete and your device should activate when the button is pressed and released. NOTE: If the indicator light blinks rapidly for two seconds and then turns to a constant light, continue with "Reprogramming" steps 6-8 to complete the programming of a rolling code equipped device (most commonly a garage door opener). - At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. - Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.) NOTE: There are 30 seconds in which to initiate step 8. - Return to the vehicle and firmly press, hold for two seconds and release the reprogrammed HomeLink(R) transceiver button. Repeat the "press/hold/release" sequence a second time, and, depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the reprogramming. The HomeLink(R) transceiver should now activate your rolling code equipped device. Reprogramming Basic HomeLink(R) Transceiver Codes (Electronic Vehicle Information Center (EVIC) Equipped Vehicles) To program a device to the HomeLink(R) transceiver using a button previously trained, follow these steps: - Press and hold the desired HomeLink(R) transceiver button. DO NOT release the button. The EVIC will display "CHANNEL X TRANSMIT" for 20 seconds and then change to "CHANNEL X TRAINING". Without releasing the HomeLink(R) transceiver button, proceed to step 2. - Position the end of your hand-held transmitter 3-8 cm (1-3 inches) away from the HomeLink(R) transceiver button while keeping the EVIC display in view. - Simultaneously press and hold both the HomeLink(R) transceiver button that you want to train and the hand-held transmitter buttons. Do not release the buttons until step 4 has been completed. The EVIC will display "CHANNEL X TRAINING", once the HomeLink(R) transceiver is programmed the EVIC will display "CHANNEL X TRAINED". X refers to the desired channel being trained (1,2 or 3). NOTE: Some gate operators and garage door openers may require you to replace this Reprogramming Step 3 with procedures noted in the "Gate Operator/Canadian Programming" section. - Once "CHANNEL X TRAINED" is displayed on the EVIC, release both buttons. Programming is now complete. When the HomeLink(R) transceiver button is subsequently pressed, "CHANNEL X TRANSMIT" is displayed on the EVIC and your device should be activated, (garage door should open). NOTE: If the EVIC display shows "CHANNEL X TRANSMIT" (where X is channel 1,2 or 3) but your device does not activate, the device may be equipped with a "rolling code" system. Continue with the following steps 5 through 7 to complete the programming of a rolling code equipped device (most commonly a garage door opener manufactured after 1995). The assistance of a second person may make the following programming steps quicker and easier. - At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. - Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.) NOTE: There are 30 seconds in which to initiate step 7. - Return to the vehicle and firmly press, hold for two seconds and release the reprogrammed HomeLink(R) transceiver button. Repeat the "press/hold/release" sequence a second time, and, depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the reprogramming. The HomeLink(R) transceiver should now activate your rolling code equipped device. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 14371 Canadian Programming/Gate Programming Canadian radio-frequency laws require transmitter signals to "time-out" (or quit) after several seconds of transmission which may not be long enough for the HomeLink(R) transceiver to pick up the signal during programming. Similar to this Canadian law, some U.S. gate operators are designed to "time-out" in the same manner. If you live in Canada or you are having difficulties programming a gate operator by using the "Programming" procedures (regardless of where you live), replace "Programming Common HomeLink(R) Transceiver Codes" step 3 with the following: NOTE: When programming a garage door opener or gate operator, it is advised to unplug the device or move the vehicle out of range during the "cycling" process to prevent possible overheating. - 3. Continue to press and hold the HomeLink(R) transceiver button while you press and release every two seconds ("cycle") your hand-held transmitter until the frequency signal has successfully been accepted. (On CMTC equipped vehicles, the indicator light will flash slowly and then rapidly.) (On EVIC equipped vehicles, the EVIC will display "CHANNEL X TRAINING" and then "CHANNEL X TRAINED".) Proceed with "Programming" step 4 to complete. Erasing Homelink(R) Transceiver Codes ERASING HOMELINK(R) TRANSCEIVER CODES NOTE: Individual channels cannot be erased. Erasing the HomeLink(R) transceiver codes will erase ALL programmed codes. Erasing Homelink(R) Transceiver Codes (Compass Mini - Trip Computer (CMTC)) Equipped Vehicles. To erase programming from all three buttons (individual buttons cannot be erased but can be "reprogrammed"), follow the step noted: - Press and hold the two outer HomeLink(R) transceiver buttons until the indicator light begins to flash-after 20 seconds. Release both buttons. Do not hold for longer that 30 seconds. HomeLink(R) is now in the train (or learning) mode and can be programmed at any time beginning with "Programming". Erasing Homelink(R) Transceiver Codes (Electronic Vehicle Information Center (EVIC)) Equipped Vehicles. To erase programming from all three buttons (individual buttons cannot be erased but can be "reprogrammed"), follow the step noted: - Press and hold the two outer HomeLink(R) transceiver buttons until the EVIC displays "CLEARING CHANNELS" , do not release the buttons until "CHANNELS CLEARED" is displayed on the EVIC (after approximately 20 seconds). Release both buttons. Do not hold for longer that 30 seconds. HomeLink(R) is now in the train (or learning) mode and can be programmed at any time beginning with "Programming". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions Memory Positioning Systems: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14376 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14377 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14378 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14379 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14380 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14381 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14382 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14383 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14384 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14385 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14386 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14387 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14388 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14389 Memory Positioning Systems: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14390 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14391 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14392 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 14393 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Description and Operation > Description Navigation System: Description and Operation Description DESCRIPTION NAVIGATION A optional navigation radio (RB4) is available on this vehicle. The navigation system allows the user to input addresses, points of interest or way points to plan a route to the desired location. The system will provide audible and visual prompts that will direct the user along the desired route. Any variances in the route will cause the navigation system to automatically recalculate the route. The Electronic Vehicle Information Center (EVIC) displays turn-by-turn directions to a programmed destination when Turn by Turn Navigation is enabled through Personal Settings. When enabled, the EVIC displays the name of the approaching road at the top of the screen, followed by an arrow to indicate the direction to turn the vehicle, and a count down to indicate the distance to the turn. TELECOMMUNICATIONS The hands-free cellular system on this vehicle uses Bluetooth(TM) technology to provide wireless communication between the operator's compatible cellular telephone and the vehicle's on-board receiver. The system uses voice recognition technology to control operation. The incoming voice is broadcast through the vehicle's radio speakers, automatically overriding any other audio signals on the front speakers when the hands-free system is in use. A microphone in the rearview mirror picks up vehicle occupant's voices. If a call is in progress when the ignition is switched off, the hands-free system will continue to operate for up to 45 seconds as part of the Accessory Relay Delay function. Thereafter, the call can continue on the hand-held telephone. The system will communicate with a telephone that is anywhere within the vehicle. However, covering the hand held phone or the hands-free phone module with a metal object may block the signal. The system will recognize up to seven telephones, each of which is given a spoken identification by the user during the setup process. The system includes Spanish and French voice recognition in addition to English. Two buttons on the rearview mirror, identified with ISO icons, control the system: A "phone" button turns the system on and off; a "voice recognition" (or voice command) button prompts the hands-free system to listen for a voice command. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Description and Operation > Description > Page 14398 Navigation System: Description and Operation Operation OPERATION Navigation The optional navigation radio system receives GPS signals from up to eight satellites to display the position and direction of the vehicle. Map information is supplied through a DVD-ROM. An electronic gyro-sensor and the vehicle's speed sensor enable the system to display the present vehicle position even in locations where GPS signals may be blocked. When a destination is selected, the navigation system uses information from the map to quickly calculate a route. As the vehicle is driven along the chosen route, the operator is guided with pictorial displays and voice prompts. TELECOMMUNICATION Two buttons on the rearview mirror, identified with ISO icons, control the system: A "phone" button turns the system on and off; a "voice recognition" (or voice command) button prompts the hands-free system to listen for a voice command. The system includes the following features: - Phone book - Stores telephone numbers for later recall by name or other verbal identification, called a voice tag, and memory location. - Four memory locations - Home, Work, Cellular and Pager. A maximum of 32 unique names or voice tags may be stored at the same time, with a different number in each of the four memory locations. - Voice tag dialing - Dials the number associated with a voice tag and memory location. - Digit dialing - Dials the telephone number by recognizing the names of the digits as they are spoken. - Receiving calls - A voice prompt notifies the user of an incoming call. A voice response accepts or rejects the call without manual intervention. - Privacy Mode - Switches the call to the handheld telephone and the hands-free system and back again using the "voice recognition" (or "voice command") button and a voice command, if desired. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations Pedal Positioning Motor: Locations Component ID: 216 Component : MOTOR-ADJUSTABLE PEDALS Connector: Name : MOTOR-ADJUSTABLE PEDALS Color : LT. GRAY # of pins : 2 Qualifier : (EXCEPT BASE) Pin Description Circuit 1 ADJUSTABLE PEDALS MOTOR REVERSE P206 18LG/LB 2 ADJUSTABLE PEDALS MOTOR FORWARD P205 18LG/WT Component Location - 49 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 14403 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 14404 Pedal Positioning Motor: Diagrams Component ID: 216 Component : MOTOR-ADJUSTABLE PEDALS Connector: Name : MOTOR-ADJUSTABLE PEDALS Color : LT. GRAY # of pins : 2 Qualifier : (EXCEPT BASE) Pin Description Circuit 1 ADJUSTABLE PEDALS MOTOR REVERSE P206 18LG/LB 2 ADJUSTABLE PEDALS MOTOR FORWARD P205 18LG/WT Component Location - 49 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 14405 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 14406 Pedal Positioning Motor: Description and Operation DESCRIPTION The Adjustable Pedals System (APS) is designed to enable the fore and aft repositioning of the brake and accelerator pedals. This results in improved ergonomics in relation to the steering wheel for taller and shorter drivers. Being able to adjust the pedal positions also allows the driver to set steering wheel tilt and seat position to the most comfortable position. The position of the brake and accelerator pedals can be adjusted without compromising safety or comfort in actuating the pedals. Change of pedal position is accomplished by means of a motor driven screw. Operating the adjustable pedal switch activates the pedal drive motor (1). The pedal drive motor turns a screw that changes the position of the brake and accelerator pedals. The pedal can be moved rearward (closer to the driver) or forward (away from driver). The brake pedal is moved on its drive screw to a position where the driver feels most comfortable. The accelerator pedal is moved at the same time and the same distance as the brake pedal. Neither the pedal drive motor (1) nor drive mechanism are subject to the mechanical stress of brake or accelerator application. - SYSTEM FEATURES: - Range of Adjustment: The pedals may be adjusted up to 3 in. (75 mm) - Pedal Adjustment Speed: 0.5 in./sec (12.5 mm/sec) - Pedal Adjustment Inhibitors: Pedal adjustment is inhibited when the vehicle is in reverse or when cruise control is activated. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Service and Repair > Removal Pedal Positioning Motor: Service and Repair Removal REMOVAL 1. Disconnect the negative battery cable. 2. Remove the kneeblocker. 3. Remove the brake light switch and discard. 4. Disconnect the adjustable pedal cables from the brake and accelerator pedals Also clutch pedal if equipped with a manual transmission. 5. Disconnect the electrical connector. 6. Unclip the cable fasteners to the support. 7. Remove the one mounting bolt (2) for the adjustable pedal motor (1). 8. Remove the adjustable pedal motor (1) with the cables. NOTE: Adjustable pedal cables are not serviceable. If they need service the adjustable pedal motor with the cables must be installed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Service and Repair > Removal > Page 14409 Pedal Positioning Motor: Service and Repair Installation INSTALLATION NOTE: Adjustable pedal cables are not serviceable. If they need service the adjustable pedal motor with the cables must be installed. 1. Install the adjustable pedal motor (1) with the cables. 2. Install the one mounting bolt (2) for the adjustable pedal motor (1). 3. Clip the cable fasteners to the support. 4. Reconnect the electrical connector. 5. Reconnect the adjustable pedal cables to the brake and accelerator pedals Also clutch pedal if equipped with a manual transmission. 6. Install the new brake light switch. 7. Install the kneeblocker. 8. Reconnect the negative battery cable. 9. Check for proper operation of the pedals. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Component ID: 457 Component : SWITCH-ADJUSTABLE PEDALS Connector: Name : SWITCH-ADJUSTABLE PEDALS Color : BLUE # of pins : 6 Qualifier : (EXCEPT BASE) Pin Description Circuit 1 ADJUSTABLE PEDALS MOTOR REARWARDP206 18LG/LB 2 ADJUSTABLE PEDALS OUTPUT A72 18RD/OR 3-4 GROUND Z146 18BK 5 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 6 ADJUSTABLE PEDALS MOTOR FORWARD P205 18LG/WT Component Location - 44 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 14413 Component Location - 50 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 14414 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 14415 Pedal Positioning Switch: Diagrams Component ID: 457 Component : SWITCH-ADJUSTABLE PEDALS Connector: Name : SWITCH-ADJUSTABLE PEDALS Color : BLUE # of pins : 6 Qualifier : (EXCEPT BASE) Pin Description Circuit 1 ADJUSTABLE PEDALS MOTOR REARWARDP206 18LG/LB 2 ADJUSTABLE PEDALS OUTPUT A72 18RD/OR 3-4 GROUND Z146 18BK 5 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 6 ADJUSTABLE PEDALS MOTOR FORWARD P205 18LG/WT Component Location - 44 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 14416 Component Location - 50 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 14417 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Service and Repair > Removal Pedal Positioning Switch: Service and Repair Removal REMOVAL 1. Remove the lower drivers side bezel (4). 2. Disconnect the electrical connector (3) from the adjustable pedal switch (2). 3. Remove the switch (2) from the lower drivers side bezel (4) by squeezing the retaining clips together and pushing the switch outwards. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Service and Repair > Removal > Page 14420 Pedal Positioning Switch: Service and Repair Installation INSTALLATION 1. Install the switch (2) to the lower drivers side bezel (4) by pushing the switch inwards seating the retaining clips to the lower drivers side bezel (4). 2. Reconnect the electrical connector (3) to the adjustable pedal switch (2). 3. Install the lower drivers side bezel (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations Amplifier: Locations Component ID: 13 Component : AMPLIFIER-RADIO Connector: Name : AMPLIFIER-RADIO C1 Color : WHITE # of pins : 20 Qualifier : (PREMIUM) Pin Description Circuit 1 LEFT INSTRUMENT PANEL SPEAKER (+) X209 18GY/OR 2 RIGHT INSTRUMENT PANEL SPEAKER (+) X208 18GY/DG 3 CENTER INSTRUMENT PANEL SPEAKER (+)X200 18GY/BR 4 FUSED B(+) A116 16YL/RD 5-6 CAN B BUS (+) D55 20WT/OR 7 LEFT REAR SPEAKER (+) X51 20DG/DB 8 RIGHT REAR SPEAKER (+) X52 20GY/DB 9 GROUND Z907 18BK 10 LEFT INSTRUMENT PANEL SPEAKER (-) X299 18GY/YL 11 RIGHT INSTRUMENT PANEL SPEAKER (-) X298 18GY/LG 12 CENTER INSTRUMENT PANEL SPEAKER (-) X290 18GY/OR 13 FUSED B(+) A116 16YL/RD 14 - 15 - 16 - 17 CAN B BUS (-) D54 20WT 18 LEFT REAR SPEAKER (-) X57 20DG/OR 19 RIGHT REAR SPEAKER (-) X58 20GY/OR 20 GROUND Z513 18BK Component Location - 46 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations > Page 14425 Connector: Name : AMPLIFIER-RADIO C2 Color : WHITE # of pins : 14 Qualifier : (PREMIUM) Pin Description Circuit 1 LEFT FRONT DOOR SPEAKER (+) X153 18DG/YL 2 RIGHT FRONT DOOR SPEAKER (+) X154 18GY/YL 3 LEFT REAR SPEAKER (+) X205 18GY/LG 4 RIGHT REAR SPEAKER (+) X206 18DG/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations > Page 14426 5-6-7 LEFT FRONT DOOR SPEAKER (-) X155 18DG/LB 8 RIGHT FRONT DOOR SPEAKER (-) X156 18GY/LB 9 LEFT REAR SPEAKER (-) X295 18GY/DG 10 - 11 - 12 RIGHT REAR SPEAKER (-) X296 18DG/GY 13 - 14 - Component Location - 46 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations > Page 14427 Amplifier: Diagrams Component ID: 13 Component : AMPLIFIER-RADIO Connector: Name : AMPLIFIER-RADIO C1 Color : WHITE # of pins : 20 Qualifier : (PREMIUM) Pin Description Circuit 1 LEFT INSTRUMENT PANEL SPEAKER (+) X209 18GY/OR 2 RIGHT INSTRUMENT PANEL SPEAKER (+) X208 18GY/DG 3 CENTER INSTRUMENT PANEL SPEAKER (+)X200 18GY/BR 4 FUSED B(+) A116 16YL/RD 5-6 CAN B BUS (+) D55 20WT/OR 7 LEFT REAR SPEAKER (+) X51 20DG/DB 8 RIGHT REAR SPEAKER (+) X52 20GY/DB 9 GROUND Z907 18BK 10 LEFT INSTRUMENT PANEL SPEAKER (-) X299 18GY/YL 11 RIGHT INSTRUMENT PANEL SPEAKER (-) X298 18GY/LG 12 CENTER INSTRUMENT PANEL SPEAKER (-) X290 18GY/OR 13 FUSED B(+) A116 16YL/RD 14 - 15 - 16 - 17 CAN B BUS (-) D54 20WT 18 LEFT REAR SPEAKER (-) X57 20DG/OR 19 RIGHT REAR SPEAKER (-) X58 20GY/OR 20 GROUND Z513 18BK Component Location - 46 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations > Page 14428 Connector: Name : AMPLIFIER-RADIO C2 Color : WHITE # of pins : 14 Qualifier : (PREMIUM) Pin Description Circuit 1 LEFT FRONT DOOR SPEAKER (+) X153 18DG/YL 2 RIGHT FRONT DOOR SPEAKER (+) X154 18GY/YL 3 LEFT REAR SPEAKER (+) X205 18GY/LG 4 RIGHT REAR SPEAKER (+) X206 18DG/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations > Page 14429 5-6-7 LEFT FRONT DOOR SPEAKER (-) X155 18DG/LB 8 RIGHT FRONT DOOR SPEAKER (-) X156 18GY/LB 9 LEFT REAR SPEAKER (-) X295 18GY/DG 10 - 11 - 12 RIGHT REAR SPEAKER (-) X296 18DG/GY 13 - 14 - Component Location - 46 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Description Amplifier: Description and Operation Description DESCRIPTION The optional Infinity premium speaker system includes a separate Infinity audio power amplifier. The amplifier is an eight-channel unit rated at 368 total output watts. The amplifier is located behind the glove box. If equipped, an additional amplifier rated at 140 watts is located under the center passenger seat. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Description > Page 14432 Amplifier: Description and Operation Operation OPERATION The power amplifier electronically increases the frequency response of the normal audio signal output from the radio amplifier in order to improve the acoustic performance of the speakers. On vehicles equipped with an amplifier, the amplifier section of the radio becomes a pre-amplifier. The amplifier receives audio signal inputs for speaker channels from the radio, then sends amplified audio outputs through six separate channels with dedicated feed and return circuits to the individual speakers. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service and Repair > Removal Amplifier: Service and Repair Removal REMOVAL INSTRUMENT PANEL MOUNTED 1. Disconnect and isolate the battery negative cable. 2. Remove glove box. 3. Remove instrument panel center bezel. 4. Disconnect electrical harness connector (4) from amplifier (2) 5. Remove mounting bolts (3) and amplifier. CENTER SEAT MOUNTED 1. Disconnect and isolate the battery negative cable. 2. Raise center seat cushion to access amplifier. 3. Remove mounting fasteners. 4. Disconnect electrical harness connector and remove amplifier. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service and Repair > Removal > Page 14435 Amplifier: Service and Repair Installation INSTALLATION INSTRUMENT PANEL MOUNTED 1. Connect electrical harness connector (4) and install amplifier (2). 2. Install and tighten mounting bolts (3). 3. Install instrument panel center bezel. 4. Install glove box. 5. Connect battery negative cable. CENTER SEAT MOUNTED 1. Connect electrical harness connector and position amplifier. 2. Install and tighten mounting fasteners. 3. Lower center seat. 4. Connect battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Service and Repair > Removal Radio Receiver: Service and Repair Removal REMOVAL NOTE: If the owner's satellite service was active before the satellite receiver module was replaced the new satellite receiver module will have to be activated. The existing satellite receiver module will have to be deactivated before the replacement satellite receiver module can be activated. To activate Sirius satellite radio service, call Sirius at their toll-free number. Please have the following information available when activating a system: - Electronic Serial Number / Sirius Identification Number (ESN/SID) of the unit to be replaced - ESN/SID of the replacement receiver - Vehicle Owner's name and address - VIN The ESN/SID number can be obtained through the radio display by following the steps in the satellite radio owners manual. The vehicle must be outside with the audio system powered on, in the satellite radio mode, to receive the activation signal. 1. Disconnect and isolate the battery negative cable. 2. Remove the glove box. 3. Disconnect the antenna cable and electrical harness connectors. 4. Remove the three mounting fasteners securing the receiver to the bracket. 5. Remove the satellite receiver. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Service and Repair > Removal > Page 14441 Radio Receiver: Service and Repair Installation INSTALLATION NOTE: If the owner's satellite service was active before the satellite receiver was replaced, the new satellite receiver will have to be activated. The existing satellite receiver will have to be deactivated before the replacement satellite receiver can be activated. To activate Sirius satellite radio service, call Sirius at their toll-free number. Please have the following information available when activating a system: - Electronic Serial Number / Sirius Identification Number (ESN/SID) of the unit to be replaced - ESN/SID of the replacement receiver - Vehicle Owner's name and address - VIN The ESN/SID number can be obtained through the radio display by following the steps in the satellite radio owners manual. The vehicle must be outside with the audio system powered on, in the satellite radio mode, to receive the activation signal. 1. Position module and install mounting fasteners. Tighten fasteners. 2. Connect antenna cable and electrical harness connector to receiver. 3. Connect battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Description and Operation > Description Radio/Stereo Noise Filter: Description and Operation Description DESCRIPTION Radio noise suppression devices are Installed on this vehicle. Radio Frequency Interference (RFI) and ElectroMagnetic Interference (EMI) can be produced by any on-board or external source of electromagnetic energy. These electromagnetic energy sources can radiate electromagnetic signals through the air, or conduct them through the vehicle electrical system. When the audio system converts RFI or EMI to an audible acoustic wave form, it is referred to as radio noise. This undesirable radio noise is generally manifested in the form of "buzzing," "hissing," "popping," "clicking," "crackling," and/or "whirring" sounds. In most cases, RFI and EMI radio noise can be suppressed using a combination of vehicle and component grounding, filtering and shielding techniques. This vehicle is equipped with factory-installed radio noise suppression devices that were designed to minimize exposure to typical sources of RFI and EMI; thereby, minimizing radio noise complaints. Factory-installed radio noise suppression is accomplished primarily through circuitry or devices that are integral to the factory-installed radios, audio power amplifiers and other on-board electrical components such as generators, wiper motors, blower motors, and fuel pumps that have been found to be potential sources of RFI or EMI. External radio noise suppression devices that are used on this vehicle to control RFI or EMI, and can be serviced, include the following: - Engine-to-body ground strap - This length of braided ground strap has an eyelet terminal connector crimped to each end. One end is secured to the engine cylinder head(s). The other is secured to the plenum at the exhaust heat shield forward/outer attaching stud. - Resistor-type spark plugs - This type of spark plug has an internal resistor connected in series between the spark plug terminal and the center electrode to help reduce the production of electromagnetic radiation that can result in radio noise. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Description and Operation > Description > Page 14446 Radio/Stereo Noise Filter: Description and Operation Operation OPERATION There are two common strategies that can be used to suppress Radio Frequency Interference (RFI) and ElectroMagnetic Interference (EMI) radio noise. The first suppression strategy involves preventing the production of RFI and EMI electromagnetic signals at their sources. The second suppression strategy involves preventing the reception of RFI and EMI electromagnetic signals by the audio system components. The use of braided ground straps in key locations is part of the RFI and EMI prevention strategy. These ground straps ensure adequate ground paths, particularly for high current components such as many of those found in the starting, charging, ignition, engine control and transmission control systems. An insufficient ground path for any of these high current components may result in radio noise caused by induced voltages created as the high current seeks alternative ground paths through components or circuits intended for use by, or in close proximity to the audio system components or circuits. Preventing the reception of RFI and EMI is accomplished by ensuring that the audio system components are correctly installed in the vehicle. Loose, corroded or improperly soldered wire harness connections, improperly routed wiring and inadequate audio system component grounding can all contribute to the reception of RFI and EMI. A properly grounded antenna body and radio chassis, as well as a shielded antenna coaxial cable with clean and tight connections will each help reduce the potential for reception of RFI and EMI. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Removal Radio/Stereo Noise Filter: Service and Repair Removal REMOVAL BED TO CAB 1. Disconnect and isolate the battery negative cable. 2. Remove the attaching bolts and strap. ENGINE TO HEAT SHIELD - 3.7L ENGINE 1. Disconnect and isolate the battery negative cable. 2. Remove the attaching bolts (2) from the cylinder heads. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Removal > Page 14449 3. Remove nut (3) from heat shield (1) and remove strap (2). ENGINE TO HEAT SHIELD - 4.7L AND 5.7L ENGINE 1. Disconnect and isolate the battery negative cable. 2. Remove the attaching bolts (2) from the cylinder heads. 3. Remove nut (3) from heat shield (1) and remove strap (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Removal > Page 14450 Radio/Stereo Noise Filter: Service and Repair Installation INSTALLATION BED TO CAB 1. Install the ground strap (3) and mounting fasteners (4). 2. Tighten mounting fasteners. 3. Connect the battery negative cable. ENGINE TO HEAT SHIELD 1. Install the mounting fastener (3) and ground strap (2) to the heat shield (1). 2. Tighten mounting fastener. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Removal > Page 14451 3. Install the retaining bolt and ground strap to the engine cylinder heads. 4. Tighten the retaining bolts. 5. Connect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Description Remote Switch: Description and Operation Description DESCRIPTION Two rocker-type switches (if equipped) are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player, CD player or CD changer (if equipped). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Description > Page 14456 Remote Switch: Description and Operation Operation OPERATION The six switches in the two remote radio switch units are normally open, resistor multiplexed momentary switches that are hard wired to the Totally Integrated Power Module (TIPM) through the clockspring. The TIPM sends a five volt reference signal to both switch units on one circuit, and senses the status of all of the switches by reading the voltage drop on a second circuit. When the TIPM senses an input (voltage drop) from any one of the remote radio switches, it sends the proper switch status messages on the Programmable Communication Interface (PCI) data bus network to the radio receiver. The electronic circuitry within the radio receiver is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. For diagnosis of the TIPM or the PCI data bus, the use of a scan tool and the proper Diagnostic Procedures information is recommended. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 14457 Remote Switch: Testing and Inspection REMOTE SWITCHES Any diagnosis of the Audio system should begin with the use of scan tool. For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the remote radio switch(es) from the steering wheel. 3. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test chart. If the remote radio switch resistances check OK, go to STEP 4. If not OK, replace the faulty switch. 4. Connect the battery negative cable. Turn the ignition switch to the On position. Check for 5 volts at the radio control mux circuit cavities of the steering wheel wire harness connectors for both remote radio switches. If OK, go to STEP 5. If not OK, repair the open or shorted radio control mux circuit to the Totally Integrated Power Module (TIPM) as required. 5. Disconnect and isolate the battery negative cable. Disconnect the 22-way instrument panel wire harness connector from the TIPM. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and a good ground. There should be no continuity. If OK, go to STEP 6. If not OK, repair the shorted remote radio switch ground circuit to the TIPM as required. 6. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and the 22-way instrument panel wire harness connector for the TIPM. There should be continuity. If OK, refer to the proper Diagnostic Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 14458 Procedures to test the TIPM and the PCI data bus. If not OK, repair the open remote radio switch ground circuit as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Removal Remote Switch: Service and Repair Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag. 3. Remove the speed control switches (2). 4. Unplug the wire harness connector from the remote radio switch (1). 5. Depress the tabs on each side of each switch and push the switch through the rear steering wheel cover. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Removal > Page 14461 Remote Switch: Service and Repair Installation INSTALLATION WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Install remote radio switch (1) to the steering wheel. 2. Connect the wire harness to the remote radio switch. 3. Install the speed control switches (2). 4. Install the driver airbag. 5. Connect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Locations > Switch-Remote Radio-Left Remote Control: Locations Switch-Remote Radio-Left Component ID: 481 Component : SWITCH-REMOTE RADIO-LEFT Connector: Name : SWITCH-REMOTE RADIO-LEFT Color : BLACK # of pins : 2 Pin Description Circuit 1 RADIO CONTROL MUX X20 22GY/WT 2 GROUND G902 22WT/BR Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Locations > Switch-Remote Radio-Left > Page 14466 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Locations > Switch-Remote Radio-Left > Page 14467 Remote Control: Locations Switch-Remote Radio-Right Component ID: 482 Component : SWITCH-REMOTE RADIO-RIGHT Connector: Name : SWITCH-REMOTE RADIO-RIGHT Color : BLACK # of pins : 2 Pin Description Circuit 1 RADIO CONTROL MUX X20 22GY/WT 2 GROUND G902 22WT/BR Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Locations > Switch-Remote Radio-Left > Page 14468 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Diagrams > Switch-Remote Radio-Left Remote Control: Diagrams Switch-Remote Radio-Left Component ID: 481 Component : SWITCH-REMOTE RADIO-LEFT Connector: Name : SWITCH-REMOTE RADIO-LEFT Color : BLACK # of pins : 2 Pin Description Circuit 1 RADIO CONTROL MUX X20 22GY/WT 2 GROUND G902 22WT/BR Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Diagrams > Switch-Remote Radio-Left > Page 14471 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Diagrams > Switch-Remote Radio-Left > Page 14472 Remote Control: Diagrams Switch-Remote Radio-Right Component ID: 482 Component : SWITCH-REMOTE RADIO-RIGHT Connector: Name : SWITCH-REMOTE RADIO-RIGHT Color : BLACK # of pins : 2 Pin Description Circuit 1 RADIO CONTROL MUX X20 22GY/WT 2 GROUND G902 22WT/BR Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Diagrams > Switch-Remote Radio-Left > Page 14473 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 08-024-07A > Nov > 07 > Audio System - Distorted Sound From Speakers Speaker: Customer Interest Audio System - Distorted Sound From Speakers NUMBER: 08-024-07 REV. A GROUP: Electrical DATE: November 30, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-024-07, DATED OCTOBER 10, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF A NEW MODEL. SUBJECT: Distorted Sound In Door Speaker, Rear Quarter Speaker Or Rear Shelf Speaker With The Radio On OVERVIEW: This bulletin involves replacing all 6x9 base (non-premium sound system) speakers in the vehicle. MODELS: 2007 - 2008 (LE) 300, Touring (International Markets) 2007 - 2008 (LX) 300, Charger, Magnum 2007 (L2) 300 (China) 2007-2008 (JS) Avenger/Sebring/Sebring Convertible 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2007 - 2008 (WK) Grand Cherokee 2007 - 2008 (WH) Grand Cherokee (International Markets) 2007 - 2008 (XK) Commander 2007 - 2008 (XH) Commander (International markets) 2007 - 2008 (DR) Ram truck 2007 - 2008 (DH/D1/DC) Ram Truck (2500 & 3500) 2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. and International Markets) **2007 (RS/RG) Town & Country/Caravan/Voyager (U.S. and International Markets)** NOTE: This bulletin applies to vehicles built between February 26, 2007 (MDH 0226XX) and September 4, 2007 (MDH 0904XX) and sales code RCB, RCG or RCD SYMPTOM/CONDITION: Some customers may experience a "distorted sound in one or more 6x9 (non-premium sound system) speakers with the radio on. DIAGNOSIS: If the Symptom/Condition is present, perform the Repair Procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 08-024-07A > Nov > 07 > Audio System - Distorted Sound From Speakers > Page 14482 PARTS REQUIRED: REPAIR PROCEDURE: 1. Replace all the 6x9 speakers in the vehicle following the procedures available in DealerCONNECT > TechCONNECT > 8 - Electrical > Radio > Speaker > Removal and Installation. Refer to table below for 6x9 speaker quantities and location details. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 08-024-07A > Nov > 07 > Audio System - Distorted Sound From Speakers > Page 14483 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 23-028-07A > Jul > 07 > Audio System - Front Door Speaker Buzzing Sounds Speaker: Customer Interest Audio System - Front Door Speaker Buzzing Sounds NUMBER: 23-028-07 REV. A GROUP: Body DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-028-07, DATED JULY 12, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND ADDS 2006 MODEL YEAR. SUBJECT: Buzz-Like Sound From Front Door Speaker Area When Radio Is On OVERVIEW: This bulletin involves determining the source of the buzz-like sound and making appropriate repairs. MODELS: **2006** - 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) SYMPTOM/CONDITION: The customer may a experience a buzz-like sound coming from the left and/or right front door when the radio is on. This sound in question will come from the interior door trim panel, in the area where the radio speaker is mounted. This condition may be misdiagnosed as a bad radio speaker. The actual cause may be the interface between the door trim panel sound insulation and the door water shield. DIAGNOSIS: 1. Turn the ignition switch to the "ON" position. DO NOT start the vehicle engine. 2. Turn the radio on. Set the bass and treble settings on the radio to their "centered position and fade the sound to the suspect door(s). 3. Adjust the radio volume to the # 20 position with music playing. 4. Determine if the buzz-like sound condition is present in the suspect front door(s). 5. Turn the ignition switch to the "OFF" position. 6. If the condition is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the interior trim panel on the affected door. Refer to TechCONNECT for detailed service procedures. Select the "Service Info tab > 23-Body > Door - Front> Trim Panel > Removal and Installation. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are INTEGRAL to the door trim panel. DO NOT pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 23-028-07A > Jul > 07 > Audio System - Front Door Speaker Buzzing Sounds > Page 14488 2. Remove the front door radio speaker from its mounting to the door. Do not disconnect the electrical connection to the speaker. 3. Turn the ignition switch to the "ON" position. DO NOT start the vehicle engine. 4. Hold the radio speaker by its magnet in your hand. 5. Operate the radio as described above in the Diagnosis section 6. Listen from the side of the speaker for the buzz-like sound. 7. Is the buzz-like sound coming from the speaker? a. If YES >>> then turn the ignition switch to the "OFF" position and replace the radio speaker. Proceed to the next step. b. If NO >>> then turn the ignition switch to the "OFF" position and install the radio speaker to the inner door panel. Proceed to the next step. 8. Loose fit the new sound insulation to the back side of the front door trim panel. DO NOT remove the original sound insulation from the door trim panel. The new sound insulation will install over the original door sound insulation and extends to the bottom of the door. Note the pieces of adhesive tape on the new sound insulation. 9. Remove the backing from a piece of adhesive tape and adhere the tape to the original sound insulation and/or back side of the trim panel. 10. Finish attaching the remain pieces of adhesive tape to the original sound insulation and/or back side of the trim panel. 11. Verify that the new sound insulation is installed correctly. 12. Install the interior door trim panel to the door. 13. Verify that the buzz-like sound is corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 08-024-07A > Nov > 07 > Audio System - Distorted Sound From Speakers Speaker: All Technical Service Bulletins Audio System - Distorted Sound From Speakers NUMBER: 08-024-07 REV. A GROUP: Electrical DATE: November 30, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-024-07, DATED OCTOBER 10, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF A NEW MODEL. SUBJECT: Distorted Sound In Door Speaker, Rear Quarter Speaker Or Rear Shelf Speaker With The Radio On OVERVIEW: This bulletin involves replacing all 6x9 base (non-premium sound system) speakers in the vehicle. MODELS: 2007 - 2008 (LE) 300, Touring (International Markets) 2007 - 2008 (LX) 300, Charger, Magnum 2007 (L2) 300 (China) 2007-2008 (JS) Avenger/Sebring/Sebring Convertible 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2007 - 2008 (WK) Grand Cherokee 2007 - 2008 (WH) Grand Cherokee (International Markets) 2007 - 2008 (XK) Commander 2007 - 2008 (XH) Commander (International markets) 2007 - 2008 (DR) Ram truck 2007 - 2008 (DH/D1/DC) Ram Truck (2500 & 3500) 2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. and International Markets) **2007 (RS/RG) Town & Country/Caravan/Voyager (U.S. and International Markets)** NOTE: This bulletin applies to vehicles built between February 26, 2007 (MDH 0226XX) and September 4, 2007 (MDH 0904XX) and sales code RCB, RCG or RCD SYMPTOM/CONDITION: Some customers may experience a "distorted sound in one or more 6x9 (non-premium sound system) speakers with the radio on. DIAGNOSIS: If the Symptom/Condition is present, perform the Repair Procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 08-024-07A > Nov > 07 > Audio System - Distorted Sound From Speakers > Page 14494 PARTS REQUIRED: REPAIR PROCEDURE: 1. Replace all the 6x9 speakers in the vehicle following the procedures available in DealerCONNECT > TechCONNECT > 8 - Electrical > Radio > Speaker > Removal and Installation. Refer to table below for 6x9 speaker quantities and location details. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 08-024-07A > Nov > 07 > Audio System - Distorted Sound From Speakers > Page 14495 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 23-028-07A > Jul > 07 > Audio System - Front Door Speaker Buzzing Sounds Speaker: All Technical Service Bulletins Audio System - Front Door Speaker Buzzing Sounds NUMBER: 23-028-07 REV. A GROUP: Body DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-028-07, DATED JULY 12, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND ADDS 2006 MODEL YEAR. SUBJECT: Buzz-Like Sound From Front Door Speaker Area When Radio Is On OVERVIEW: This bulletin involves determining the source of the buzz-like sound and making appropriate repairs. MODELS: **2006** - 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) SYMPTOM/CONDITION: The customer may a experience a buzz-like sound coming from the left and/or right front door when the radio is on. This sound in question will come from the interior door trim panel, in the area where the radio speaker is mounted. This condition may be misdiagnosed as a bad radio speaker. The actual cause may be the interface between the door trim panel sound insulation and the door water shield. DIAGNOSIS: 1. Turn the ignition switch to the "ON" position. DO NOT start the vehicle engine. 2. Turn the radio on. Set the bass and treble settings on the radio to their "centered position and fade the sound to the suspect door(s). 3. Adjust the radio volume to the # 20 position with music playing. 4. Determine if the buzz-like sound condition is present in the suspect front door(s). 5. Turn the ignition switch to the "OFF" position. 6. If the condition is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the interior trim panel on the affected door. Refer to TechCONNECT for detailed service procedures. Select the "Service Info tab > 23-Body > Door - Front> Trim Panel > Removal and Installation. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are INTEGRAL to the door trim panel. DO NOT pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 23-028-07A > Jul > 07 > Audio System - Front Door Speaker Buzzing Sounds > Page 14500 2. Remove the front door radio speaker from its mounting to the door. Do not disconnect the electrical connection to the speaker. 3. Turn the ignition switch to the "ON" position. DO NOT start the vehicle engine. 4. Hold the radio speaker by its magnet in your hand. 5. Operate the radio as described above in the Diagnosis section 6. Listen from the side of the speaker for the buzz-like sound. 7. Is the buzz-like sound coming from the speaker? a. If YES >>> then turn the ignition switch to the "OFF" position and replace the radio speaker. Proceed to the next step. b. If NO >>> then turn the ignition switch to the "OFF" position and install the radio speaker to the inner door panel. Proceed to the next step. 8. Loose fit the new sound insulation to the back side of the front door trim panel. DO NOT remove the original sound insulation from the door trim panel. The new sound insulation will install over the original door sound insulation and extends to the bottom of the door. Note the pieces of adhesive tape on the new sound insulation. 9. Remove the backing from a piece of adhesive tape and adhere the tape to the original sound insulation and/or back side of the trim panel. 10. Finish attaching the remain pieces of adhesive tape to the original sound insulation and/or back side of the trim panel. 11. Verify that the new sound insulation is installed correctly. 12. Install the interior door trim panel to the door. 13. Verify that the buzz-like sound is corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Center Speaker: Locations Speaker-Instrument Panel-Center Component ID: 449 Component : SPEAKER-INSTRUMENT PANEL-CENTER Connector: Name : SPEAKER-INSTRUMENT PANEL-CENTER Color : WHITE # of pins : 2 Qualifier : (SLT/SLT+) Pin Description Circuit 1 CENTER INSTRUMENT PANEL SPEAKER (+)X200 18GY/BR 2 CENTER INSTRUMENT PANEL SPEAKER (-) X290 18GY/OR Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Center > Page 14503 Component Location - 46 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Center > Page 14504 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Center > Page 14505 Speaker: Locations Speaker-Instrument Panel-Left Component ID: 450 Component : SPEAKER-INSTRUMENT PANEL-LEFT Connector: Name : SPEAKER-INSTRUMENT PANEL-LEFT Color : WHITE # of pins : 2 Qualifier : (SLT/SLT+) Pin Description Circuit 1 LEFT INSTRUMENT PANEL SPEAKER (+) X209 18GY/OR 2 LEFT INSTRUMENT PANEL SPEAKER (-) X299 18GY/YL Component Location - 46 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Center > Page 14506 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Center > Page 14507 Speaker: Locations Speaker-Instrument Panel-Right Component ID: 451 Component : SPEAKER-INSTRUMENT PANEL-RIGHT Connector: Name : SPEAKER-INSTRUMENT PANEL-RIGHT Color : WHITE # of pins : 2 Qualifier : (SLT/SLT+) Pin Description Circuit 1 RIGHT INSTRUMENT PANEL SPEAKER (+) X208 18GY/DG 2 RIGHT INSTRUMENT PANEL SPEAKER (-) X298 18GY/LG Component Location - 46 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Center > Page 14508 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Center > Page 14509 Speaker: Locations Speaker-Left Front Door Component ID: 452 Component : SPEAKER-LEFT FRONT DOOR Connector: Name : SPEAKER-LEFT FRONT DOOR Color : WHITE # of pins : 3 Pin Description Circuit 1 LEFT FRONT DOOR SPEAKER (-) X155 18DG/LB 2-3 LEFT FRONT DOOR SPEAKER (+) X153 18DG/YL Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Center > Page 14510 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Center > Page 14511 Speaker: Locations Speaker-Instrument Panel-Center Component ID: 449 Component : SPEAKER-INSTRUMENT PANEL-CENTER Connector: Name : SPEAKER-INSTRUMENT PANEL-CENTER Color : WHITE # of pins : 2 Qualifier : (SLT/SLT+) Pin Description Circuit 1 CENTER INSTRUMENT PANEL SPEAKER (+)X200 18GY/BR 2 CENTER INSTRUMENT PANEL SPEAKER (-) X290 18GY/OR Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Center > Page 14512 Component Location - 46 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Center > Page 14513 Speaker-Instrument Panel-Left Component ID: 450 Component : SPEAKER-INSTRUMENT PANEL-LEFT Connector: Name : SPEAKER-INSTRUMENT PANEL-LEFT Color : WHITE # of pins : 2 Qualifier : (SLT/SLT+) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Center > Page 14514 Pin Description Circuit 1 LEFT INSTRUMENT PANEL SPEAKER (+) X209 18GY/OR 2 LEFT INSTRUMENT PANEL SPEAKER (-) X299 18GY/YL Component Location - 46 Speaker-Instrument Panel-Right Component ID: 451 Component : SPEAKER-INSTRUMENT PANEL-RIGHT Connector: Name : SPEAKER-INSTRUMENT PANEL-RIGHT Color : WHITE # of pins : 2 Qualifier : (SLT/SLT+) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Center > Page 14515 Pin Description Circuit 1 RIGHT INSTRUMENT PANEL SPEAKER (+) X208 18GY/DG 2 RIGHT INSTRUMENT PANEL SPEAKER (-) X298 18GY/LG Component Location - 46 Speaker-Left Front Door Component ID: 452 Component : SPEAKER-LEFT FRONT DOOR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Center > Page 14516 Connector: Name : SPEAKER-LEFT FRONT DOOR Color : WHITE # of pins : 3 Pin Description Circuit 1 LEFT FRONT DOOR SPEAKER (-) X155 18DG/LB 2-3 LEFT FRONT DOOR SPEAKER (+) X153 18DG/YL Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Center > Page 14517 Speaker-Left Rear Component ID: 453 Component : SPEAKER-LEFT REAR Connector: Name : SPEAKER-LEFT REAR Color : WHITE # of pins : 3 Pin Description Circuit Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Center > Page 14518 1 LEFT REAR SPEAKER (+) X205 18GY/LG 2-3 LEFT REAR SPEAKER (-) X295 18GY/DG Component Location - 58 Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Center > Page 14519 Speaker-Right Front Door Component ID: 454 Component : SPEAKER-RIGHT FRONT DOOR Connector: Name : SPEAKER-RIGHT FRONT DOOR Color : WHITE # of pins : 3 Pin Description Circuit Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Center > Page 14520 1 RIGHT FRONT DOOR SPEAKER (-) X156 18GY/LB 2-3 RIGHT FRONT DOOR SPEAKER (+) X154 18DG/YL 3 RIGHT FRONT DOOR SPEAKER (+) X154 18GY/YL Component Location - 56 Speaker-Right Rear Component ID: 455 Component : SPEAKER-RIGHT REAR Connector: Name : SPEAKER-RIGHT REAR Color : WHITE # of pins : 3 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Center > Page 14521 Pin Description Circuit 1 RIGHT REAR SPEAKER (+) X206 18GY/LG Pin Description Circuit 1 RIGHT REAR SPEAKER (+) X206 18DG/LG 2-3 RIGHT REAR SPEAKER (-) X296 18GY/DG 3 RIGHT REAR SPEAKER (-) X296 18DG/GY Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Speaker-Instrument Panel-Center > Page 14522 Component Location - 61 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Center Speaker: Diagrams Speaker-Instrument Panel-Center Component ID: 449 Component : SPEAKER-INSTRUMENT PANEL-CENTER Connector: Name : SPEAKER-INSTRUMENT PANEL-CENTER Color : WHITE # of pins : 2 Qualifier : (SLT/SLT+) Pin Description Circuit 1 CENTER INSTRUMENT PANEL SPEAKER (+)X200 18GY/BR 2 CENTER INSTRUMENT PANEL SPEAKER (-) X290 18GY/OR Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Center > Page 14525 Component Location - 46 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Center > Page 14526 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Center > Page 14527 Speaker: Diagrams Speaker-Instrument Panel-Left Component ID: 450 Component : SPEAKER-INSTRUMENT PANEL-LEFT Connector: Name : SPEAKER-INSTRUMENT PANEL-LEFT Color : WHITE # of pins : 2 Qualifier : (SLT/SLT+) Pin Description Circuit 1 LEFT INSTRUMENT PANEL SPEAKER (+) X209 18GY/OR 2 LEFT INSTRUMENT PANEL SPEAKER (-) X299 18GY/YL Component Location - 46 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Center > Page 14528 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Center > Page 14529 Speaker: Diagrams Speaker-Instrument Panel-Right Component ID: 451 Component : SPEAKER-INSTRUMENT PANEL-RIGHT Connector: Name : SPEAKER-INSTRUMENT PANEL-RIGHT Color : WHITE # of pins : 2 Qualifier : (SLT/SLT+) Pin Description Circuit 1 RIGHT INSTRUMENT PANEL SPEAKER (+) X208 18GY/DG 2 RIGHT INSTRUMENT PANEL SPEAKER (-) X298 18GY/LG Component Location - 46 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Center > Page 14530 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Center > Page 14531 Speaker: Diagrams Speaker-Left Front Door Component ID: 452 Component : SPEAKER-LEFT FRONT DOOR Connector: Name : SPEAKER-LEFT FRONT DOOR Color : WHITE # of pins : 3 Pin Description Circuit 1 LEFT FRONT DOOR SPEAKER (-) X155 18DG/LB 2-3 LEFT FRONT DOOR SPEAKER (+) X153 18DG/YL Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Center > Page 14532 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Center > Page 14533 Speaker: Diagrams Speaker-Instrument Panel-Center Component ID: 449 Component : SPEAKER-INSTRUMENT PANEL-CENTER Connector: Name : SPEAKER-INSTRUMENT PANEL-CENTER Color : WHITE # of pins : 2 Qualifier : (SLT/SLT+) Pin Description Circuit 1 CENTER INSTRUMENT PANEL SPEAKER (+)X200 18GY/BR 2 CENTER INSTRUMENT PANEL SPEAKER (-) X290 18GY/OR Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Center > Page 14534 Component Location - 46 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Center > Page 14535 Speaker-Instrument Panel-Left Component ID: 450 Component : SPEAKER-INSTRUMENT PANEL-LEFT Connector: Name : SPEAKER-INSTRUMENT PANEL-LEFT Color : WHITE # of pins : 2 Qualifier : (SLT/SLT+) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Center > Page 14536 Pin Description Circuit 1 LEFT INSTRUMENT PANEL SPEAKER (+) X209 18GY/OR 2 LEFT INSTRUMENT PANEL SPEAKER (-) X299 18GY/YL Component Location - 46 Speaker-Instrument Panel-Right Component ID: 451 Component : SPEAKER-INSTRUMENT PANEL-RIGHT Connector: Name : SPEAKER-INSTRUMENT PANEL-RIGHT Color : WHITE # of pins : 2 Qualifier : (SLT/SLT+) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Center > Page 14537 Pin Description Circuit 1 RIGHT INSTRUMENT PANEL SPEAKER (+) X208 18GY/DG 2 RIGHT INSTRUMENT PANEL SPEAKER (-) X298 18GY/LG Component Location - 46 Speaker-Left Front Door Component ID: 452 Component : SPEAKER-LEFT FRONT DOOR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Center > Page 14538 Connector: Name : SPEAKER-LEFT FRONT DOOR Color : WHITE # of pins : 3 Pin Description Circuit 1 LEFT FRONT DOOR SPEAKER (-) X155 18DG/LB 2-3 LEFT FRONT DOOR SPEAKER (+) X153 18DG/YL Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Center > Page 14539 Speaker-Left Rear Component ID: 453 Component : SPEAKER-LEFT REAR Connector: Name : SPEAKER-LEFT REAR Color : WHITE # of pins : 3 Pin Description Circuit Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Center > Page 14540 1 LEFT REAR SPEAKER (+) X205 18GY/LG 2-3 LEFT REAR SPEAKER (-) X295 18GY/DG Component Location - 58 Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Center > Page 14541 Speaker-Right Front Door Component ID: 454 Component : SPEAKER-RIGHT FRONT DOOR Connector: Name : SPEAKER-RIGHT FRONT DOOR Color : WHITE # of pins : 3 Pin Description Circuit Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Center > Page 14542 1 RIGHT FRONT DOOR SPEAKER (-) X156 18GY/LB 2-3 RIGHT FRONT DOOR SPEAKER (+) X154 18DG/YL 3 RIGHT FRONT DOOR SPEAKER (+) X154 18GY/YL Component Location - 56 Speaker-Right Rear Component ID: 455 Component : SPEAKER-RIGHT REAR Connector: Name : SPEAKER-RIGHT REAR Color : WHITE # of pins : 3 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Center > Page 14543 Pin Description Circuit 1 RIGHT REAR SPEAKER (+) X206 18GY/LG Pin Description Circuit 1 RIGHT REAR SPEAKER (+) X206 18DG/LG 2-3 RIGHT REAR SPEAKER (-) X296 18GY/DG 3 RIGHT REAR SPEAKER (-) X296 18DG/GY Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker-Instrument Panel-Center > Page 14544 Component Location - 61 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation > Description Speaker: Description and Operation Description DESCRIPTION STANDARD The standard equipment speaker system includes speakers in four locations. One 15.2 X 22.8 centimeter (6 X 9 inch) full-range speaker is located in each front door. There is also one full-range 13.3 centimeter (5.25 inch) diameter full-range speaker located in each rear door (quad cab) or B-pillar (regular cab). PREMIUM The optional premium speaker system features eleven Premium model speakers in seven locations. Each of the standard speakers is replaced with Premium model speakers. One 8.8 centimeter (3.50 inch) diameter speaker is located on each end of the instrument panel top pad. One 6.3 centimeter (2.50 inch) diameter speaker is located in the center of the instrument panel top pad. One 15.2 X 22.8 centimeter (6 X 9 inch) Premium speaker is located in each front door. There is also one coaxial 13.3 centimeter (5.25 inch) diameter Premium full-range speaker located in each rear door (quad cab) or B-pillar (regular cab). The premium speaker system also includes a power amplifier mounted behind the glove box. The total available power of the premium speaker system is 368 watts. If equipped, a 25.4 centimeter (10 inch) subwoofer is located behind the center passenger seat along with a amplifier (rated at 150 watts) located under the center passenger seat. The total available power if equipped with the subwoofer and second power amplifier is 518 watts. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation > Description > Page 14547 Speaker: Description and Operation Operation OPERATION Two wires connected to each speaker, one feed circuit (+) and one return circuit (-), allow the audio output signal electrical current to flow through the voice coil. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation > Page 14548 Speaker: Testing and Inspection SPEAKER Any diagnosis of the Audio system should begin with the use of a scan tool. Refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. CAUTION: The speaker output of the radio is a "floating ground" system. Do not allow any speaker lead to short to ground, as damage to the radio and/or amplifier may result. 1. If all speakers are inoperative, check the fuses in the Totally Integrated Power Module (TIPM). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check the amplifier fuse (if equipped) in the TIPM. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 3. Turn the ignition switch to the ON position. Turn the radio receiver ON. Adjust the balance and fader control controls to check the performance of each individual speaker. Note the speaker locations that are not performing correctly. Go to Step 4. 4. Turn the radio receiver OFF. Turn the ignition OFF. Disconnect and isolate the battery negative cable. If vehicle is not equipped with an amplifier, remove the radio receiver. If vehicle is equipped with an amplifier, disconnect wire harness connector at output side of amplifier. Go to Step 5. 5. Check both the speaker feed (+) circuit and return (-) circuit cavities for the inoperative speaker at the radio receiver wire harness connector for continuity to ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted speaker feed (+) and/or return (-) circuits(s) to the speaker as required. 6. Disconnect wire harness connector at the inoperative speaker. Check for continuity between the speaker feed (+) circuit cavities of the radio receiver wire harness connector or if equipped, the amplifier wire harness connector and the speaker wire harness connector. Repeat the check between the speaker return (-) circuit cavities of the radio receiver wire harness connector and the speaker wire harness connector. In each case, there should be continuity. If OK, replace the faulty speaker. If not OK, repair the open speaker feed (+) and/or return (-) circuits(s) as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Removal Speaker: Service and Repair Removal REMOVAL FRONT DOOR SPEAKER 1. Disconnect and isolate the battery negative cable. 2. Remove front door trim panel. 3. Remove mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTRUMENT PANEL CENTER SPEAKER 1. Disconnect and isolate the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Removal > Page 14551 2. Remove instrument panel top cover. 3. Remove speaker mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTRUMENT PANEL END SPEAKER 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. 3. Remove speaker mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. REAR CAB SIDE SPEAKER 1. Disconnect and isolate the battery negative cable. 2. Remove B-pillar lower trim. 3. Remove speaker mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. REAR DOOR SPEAKER Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Removal > Page 14552 1. Disconnect and isolate the battery negative cable. 2. Remove rear door trim panel. 3. Remove speaker mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. SUBWOOFER - REGULAR CAB 1. Disconnect and isolate the battery negative cable. 2. Remove mounting fasteners to subwoofer housing. 3. Disconnect electrical harness connector. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Removal > Page 14553 4. Remove subwoofer from vehicle. SUBWOOFER - QUAD CAB 1. Disconnect and isolate the battery negative cable. 2. Raise left rear seat to access subwoofer. 3. Disconnect electrical harness connector. 4. Remove mounting fasteners and remove subwoofer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Removal > Page 14554 Speaker: Service and Repair Installation INSTALLATION FRONT DOOR SPEAKER 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install front door trim panel. 4. Connect battery negative cable. INSTRUMENT PANEL CENTER SPEAKER 1. Connect electrical harness connector and install speaker. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Removal > Page 14555 2. Install and tighten mounting fasteners. 3. Install instrument panel top cover. 4. Connect battery negative cable. INSTRUMENT PANEL END SPEAKER 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install instrument panel top cover. 4. Connect battery negative cable. REAR CAB SIDE SPEAKER 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install B-pillar lower trim. 4. Connect battery negative cable. REAR DOOR SPEAKER Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Removal > Page 14556 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install rear door trim panel. 4. Connect battery negative cable. SUBWOOFER - REGULAR CAB 1. Position subwoofer housing into the vehicle. 2. Connect electrical harness connector. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Removal > Page 14557 3. Install mounting fasteners. 4. Connect battery negative cable. SUBWOOFER - QUAD CAB 1. Position subwoofer to vehicle. 2. Connect electrical harness connector. 3. Install and tighten mounting fasteners. 4. Lower seat. 5. Connect battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest for Alarm Module: > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood Alarm Module: Customer Interest Antitheft System - Goes Off When Opening The Hood NUMBER: 08-040-06 GROUP: Electrical DATE: September 06, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: Vehicle Theft Security System Alarm May Alert When Hood Is Opened OVERVIEW: This bulletin involves selectively erasing and reprogramming the Cabin Compartment Node Module (CCN) with new software. MODELS: 2007 (DR/DH/D1/DC) Ram Truck NOTE: This bulletin applies to vehicles equipped with a remote start system (sales code XBM) prior to October 10, 2006 (MDH 1010XX). SYMPTOM/CONDITION: The Vehicle Theft Security System (VTSS) may alert (flash lights and/or sound horn) if one of the following occurs: a. The customer arms the VTSS and then reaches through an open window, pulls on the hood release, and fully opens the vehicle hood. b. The customer releases the hood but not enough to open the hood ajar switch, arms the VTSS, and then fully opens the vehicle hood. c. The customer opens the hood, arms the VTSS, the vehicle communications bus goes in to "sleep mode" (may take 10 minutes), then the "LOCK" button on the key fob is depressed. The hood ajar switch is not part of the VTSS used on domestic use vehicles. The hood ajar switch is used for export vehicles equipped with the Vehicle Theft Alarm (VTA) system. DIAGNOSIS: 1. Connect the StarSCAN(R) to the vehicle. 2. Power up the StarSCAN(R) and obtain the HOME menu. 3. From the HOME menu select "ECU VIEW". 4. Select "CCN - Cabin Compartment". 5. Select "More Options". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest for Alarm Module: > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 14567 6. Select "ECU Flash" 7. Read and record the software part number that is display with "Resident Flash File For Part". 8. Is the software part number 05172187AC (or later)? a. If YES >>> then STOP. This bulletin does not apply. Further diagnosis is required. b. If NO >>> then perform the Repair Procedure. NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the CCN in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash CCN" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest for Alarm Module: > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 14568 13. Highlight the listed calibration. 14. Select "Update Controller". Follow on screen instructions. 15. When the CCN update is complete, select "OK". 16. Verify the part number at the top of the "Flash CCN" screen has updated to the new part number. NOTE: Due to the CCN programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alarm Module: > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood Alarm Module: All Technical Service Bulletins Antitheft System - Goes Off When Opening The Hood NUMBER: 08-040-06 GROUP: Electrical DATE: September 06, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: Vehicle Theft Security System Alarm May Alert When Hood Is Opened OVERVIEW: This bulletin involves selectively erasing and reprogramming the Cabin Compartment Node Module (CCN) with new software. MODELS: 2007 (DR/DH/D1/DC) Ram Truck NOTE: This bulletin applies to vehicles equipped with a remote start system (sales code XBM) prior to October 10, 2006 (MDH 1010XX). SYMPTOM/CONDITION: The Vehicle Theft Security System (VTSS) may alert (flash lights and/or sound horn) if one of the following occurs: a. The customer arms the VTSS and then reaches through an open window, pulls on the hood release, and fully opens the vehicle hood. b. The customer releases the hood but not enough to open the hood ajar switch, arms the VTSS, and then fully opens the vehicle hood. c. The customer opens the hood, arms the VTSS, the vehicle communications bus goes in to "sleep mode" (may take 10 minutes), then the "LOCK" button on the key fob is depressed. The hood ajar switch is not part of the VTSS used on domestic use vehicles. The hood ajar switch is used for export vehicles equipped with the Vehicle Theft Alarm (VTA) system. DIAGNOSIS: 1. Connect the StarSCAN(R) to the vehicle. 2. Power up the StarSCAN(R) and obtain the HOME menu. 3. From the HOME menu select "ECU VIEW". 4. Select "CCN - Cabin Compartment". 5. Select "More Options". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alarm Module: > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 14574 6. Select "ECU Flash" 7. Read and record the software part number that is display with "Resident Flash File For Part". 8. Is the software part number 05172187AC (or later)? a. If YES >>> then STOP. This bulletin does not apply. Further diagnosis is required. b. If NO >>> then perform the Repair Procedure. NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the CCN in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash CCN" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alarm Module: > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 14575 13. Highlight the listed calibration. 14. Select "Update Controller". Follow on screen instructions. 15. When the CCN update is complete, select "OK". 16. Verify the part number at the top of the "Flash CCN" screen has updated to the new part number. NOTE: Due to the CCN programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Component ID: 211 Component : MODULE-SENTRY KEY REMOTE ENTRY Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z109 20BK/GY 5 FUSED B(+) A114 18GY/RD 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT 8-Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 14579 Component Location - 41 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 14580 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 14581 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 14582 Keyless Entry Module: Diagrams Component ID: 211 Component : MODULE-SENTRY KEY REMOTE ENTRY Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z109 20BK/GY 5 FUSED B(+) A114 18GY/RD 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT 8-Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 14583 Component Location - 41 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 14584 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 14585 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry Keyless Entry Module: Description and Operation Module-Remote Keyless Entry Description DESCRIPTION When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 Km/h(15 mph) will also cancel the panic event. Operation OPERATION Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 14588 Keyless Entry Module: Description and Operation Sentry Key Remote Entry Module Description DESCRIPTION The Sentry Key REmote Entry Module (SKREEM) (1) is sometimes referred to as the Wireless Control Module (WCM). The SKREEM is the primary component of the Sentry Key Immobilizer System (SKIS). It is also the receiver for the Remote Keyless Entry (RKE) system. The SKREEM is located on the right side of the steering column, near the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM has an integral molded plastic halo-like antenna ring (4) that extends from the bottom. When the SKREEM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle (3) is located just behind the antenna ring on the bottom of the SKREEM housing. An integral molded plastic mounting tab (2) on the rear corner of the SKREEM housing has a hole in the center through which a screw passes to secure the unit to the steering column. The SKREEM is connected to the vehicle electrical system through a single take out and connector of the instrument panel wire harness. Two SKREEM modules are used: one for vehicles equipped with RKE only, and one for vehicles equipped with RKE and SKIS. The SKREEM cannot be adjusted or repaired. If ineffective or damaged, the entire SKREEM unit must be replaced. Operation OPERATION The Sentry Key REmote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver. The SKREEM communicates over the Controller Area Network (CAN) data bus with the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), the Powertrain Control Module (PCM)/Engine Control Module (ECM) or the diagnostic scan tool. The SKREEM and the PCM/ECM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS) disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKREEM or the PCM/ECM. However, the use of this strategy also means that replacement of either the SKREEM or the PCM/ECM units will require a system initialization procedure to restore system operation. The SKREEM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM. For added system security, each SKREEM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM or ECM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM. Therefore, the Secret Key code is a common element that is found in every component of the SKIS. Another security code called a PIN, is used to gain access to the SKREEM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKREEM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM or ECM during SKIS initialization. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 14589 In the event that a SKREEM replacement is required, the Secret Key code can be transferred to the new SKREEM from the PCM or ECM using a diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the ON position, the SKREEM transmits an RF signal to excite the transponder in the ignition key. The SKREEM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM sends an electronic valid key message to the PCM/ECM over the CAN bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the SKREEM sends an invalid key message to the PCM/ECM. The PCM/ECM will enable or disable engine operation based upon the status of the SKREEM messages. It is important to note that the default condition in the PCM or ECM is an invalid key; therefore, if no message is received from the SKREEM by the PCM or ECM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM also sends security indicator request messages to the EMIC over the CAN data bus to tell the EMIC how to operate the security indicator. The security indicator request message from the SKREEM tells the EMIC to turn the indicator ON for about three seconds each time the ignition switch is turned to the ON position as a bulb test. After completion of the bulb test, the SKREEM sends security indicator request messages to the EMIC to turn the indicator OFF, turn the indicator ON, or to flash the indicator ON and OFF. If the security indicator flashes or stays ON solid after the bulb test, it signifies a SKIS fault. If the SKREEM detects a system malfunction or the SKIS has become ineffective, the security indicator will stay ON solid. If the SKREEM detects an invalid key or if a key transponder-related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM will also send messages to the EMIC to flash the security indicator whenever the Customer Learn programming mode is being utilized. The SKIS performs a self-test each time the ignition switch is turned to the ON position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM memory if a system malfunction is detected. The hard wired circuits of the SKREEM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SKREEM or the electronic controls or communication between other modules and devices that provide some features of the SKIS. The most reliable, efficient, and accurate means to diagnose the SKREEM or the electronic controls and communication related to SKREEM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Page 14590 Keyless Entry Module: Testing and Inspection REMOTE KEYLESS ENTRY MODULE The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Removal Keyless Entry Module: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, push inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 14593 8. Disconnect the wire harness connector (2) from the Sentry Key REmote Entry Module (SKREEM) (1). 9. Remove the screw (3) that secures the SKREEM (1) to the steering column (2). 10. Disengage the antenna ring from around the ignition lock cylinder housing and remove the SKREEM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 14594 Keyless Entry Module: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the Sentry Key REmote Entry Module (SKREEM) (1) onto the steering column (2) with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw (3) that secures the SKREEM to the steering column housing. Tighten the screw to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the SKREEM (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 14595 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). 10. Reconnect the battery negative cable. NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS) if the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations Voice Activation Module: Locations Component ID: 206 Component : MODULE-HANDS FREE Connector: Name : MODULE-HANDS FREE Color : DK. GRAY # of pins : 22 Pin Description Circuit 1 FUSED B(+) A114 18GY/RD 2-3-4 CAN B BUS (-) D54 20WT 5 MICROPHONE 2 IN (+) X722 20LB/DG 6-7-- 8 LEFT AUDIO OUTPUT X716 20GY/TN 9 RIGHT AUDIO OUTPUT X776 20TN/GY 10 COMMON AUDIO OUTPUT X795 20DG 11 - 12 - 13 - 14 CAN B BUS (+) D55 20WT/OR 15 VOICE RECOGNITION/PHONE SWITCH SIGNAL X730 20GY/YL 16 MICROPHONE 1 IN (+) X712 20DG/LB 17 MICROPHONE IN (-) X792 20LB/DG 18 - 19 - 20 MICROPHONE FEED X793 20DG/YL 21 SENSOR GROUND X835 20OR/GY 22 GROUND Z970 18BK Component Location - 46 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 14599 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 14600 Voice Activation Module: Diagrams Component ID: 206 Component : MODULE-HANDS FREE Connector: Name : MODULE-HANDS FREE Color : DK. GRAY # of pins : 22 Pin Description Circuit 1 FUSED B(+) A114 18GY/RD 2-3-4 CAN B BUS (-) D54 20WT 5 MICROPHONE 2 IN (+) X722 20LB/DG 6-7-- 8 LEFT AUDIO OUTPUT X716 20GY/TN 9 RIGHT AUDIO OUTPUT X776 20TN/GY 10 COMMON AUDIO OUTPUT X795 20DG 11 - 12 - 13 - 14 CAN B BUS (+) D55 20WT/OR 15 VOICE RECOGNITION/PHONE SWITCH SIGNAL X730 20GY/YL 16 MICROPHONE 1 IN (+) X712 20DG/LB 17 MICROPHONE IN (-) X792 20LB/DG 18 - 19 - 20 MICROPHONE FEED X793 20DG/YL 21 SENSOR GROUND X835 20OR/GY 22 GROUND Z970 18BK Component Location - 46 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 14601 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Description and Operation Winch Relay: Description and Operation DESCRIPTION RELAY PACK Electrical operation of the control assembly consists of four heavy duty relays, a thermal-switch located on the motor armature brush holder and a Low Voltage Interrupt (LVI) located in the control assembly. The thermal-switch interrupts the power-in function and the LVI affects both the power-in and power-out functions and must be reset by allowing the charging circuit voltage to rise above 10 volts for more than 30 seconds. The thermal switch is reset only by allowing the winch motor to cool adequately (about 30 minutes). Relay number 1 and 3 control current flow through the field windings and relay number 2 and 4 supply current to the motor armature. Operation In the power-out mode, relay number 2 and 3 are energized by the remote control switch. Current flows from the positive battery terminal through relay number 3 then through the black motor cable to the number 2 and number 1 field windings. From the black motor cable current then flows through solenoid number 2 to the motor armature to ground. In power-in mode, relay number 1 and 4 are energized. Current again flows from the battery positive cable, but this time current flows through solenoid number 1 then through field winding number 1. Current flowing in the reverse direction through the field windings cause the motor to turn in the opposite direction. From the red motor cable current then flows through relay number 4 to the black cable going to the motor armature to ground. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay Winch Relay: Service and Repair Relay Removal REMOVAL 1. Remove the relay pack (1). 2. Remove the nuts (2 & 3), disconnect the cables and remove the bus straps (4). NOTE: Relay #4 shown, all others similar. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay > Page 14607 3. Remove the nuts (1) and disconnect the control wires (2). 4. Slide the relay (1) out of the retaining tab (2) and remove. Installation INSTALLATION NOTE: Relay #4 shown, all others similar. 1. Slide the relay (1) into the retaining tab (2). 2. Install the control wires (2) and install the nuts (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay > Page 14608 3. Tighten the nuts to 3 Nm (25 in. lbs.). 4. Install the bus straps (4) and connect the cables. 5. Install the nuts (2 & 3) and tighten to 9.5 Nm (85 in. lbs.). 6. Install the relay pack (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay > Page 14609 Winch Relay: Service and Repair Relay Pack Removal REMOVAL 1. Disconnect and isolate battery negative cable (3). 2. Remove the winch assembly (2). 3. Remove the nut and disconnect the red battery positive cable (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay > Page 14610 NOTE: Relay #4 shown, all others similar. 4. Remove the control wire nuts (1) and disconnect the control wires (2) from each relay. Installation INSTALLATION NOTE: Relay #4 shown, all others similar. 1. Install the control wires (2) to all the relays and install the nuts (1). 2. Tighten the nuts to 3 Nm (25 in. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay > Page 14611 3. Install the red battery positive cable (1) and install the switch wire. 4. Install the nut and tighten to 10 Nm (85 in. lbs.). 5. Install the relay pack cover (1) and install the three screws (2). 6. Install the winch assembly (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay > Page 14612 7. Connect the battery negative cable (3) and verify winch operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Customer Interest for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood Hood Sensor/Switch (For Alarm): Customer Interest Antitheft System - Goes Off When Opening The Hood NUMBER: 08-040-06 GROUP: Electrical DATE: September 06, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: Vehicle Theft Security System Alarm May Alert When Hood Is Opened OVERVIEW: This bulletin involves selectively erasing and reprogramming the Cabin Compartment Node Module (CCN) with new software. MODELS: 2007 (DR/DH/D1/DC) Ram Truck NOTE: This bulletin applies to vehicles equipped with a remote start system (sales code XBM) prior to October 10, 2006 (MDH 1010XX). SYMPTOM/CONDITION: The Vehicle Theft Security System (VTSS) may alert (flash lights and/or sound horn) if one of the following occurs: a. The customer arms the VTSS and then reaches through an open window, pulls on the hood release, and fully opens the vehicle hood. b. The customer releases the hood but not enough to open the hood ajar switch, arms the VTSS, and then fully opens the vehicle hood. c. The customer opens the hood, arms the VTSS, the vehicle communications bus goes in to "sleep mode" (may take 10 minutes), then the "LOCK" button on the key fob is depressed. The hood ajar switch is not part of the VTSS used on domestic use vehicles. The hood ajar switch is used for export vehicles equipped with the Vehicle Theft Alarm (VTA) system. DIAGNOSIS: 1. Connect the StarSCAN(R) to the vehicle. 2. Power up the StarSCAN(R) and obtain the HOME menu. 3. From the HOME menu select "ECU VIEW". 4. Select "CCN - Cabin Compartment". 5. Select "More Options". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Customer Interest for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 14622 6. Select "ECU Flash" 7. Read and record the software part number that is display with "Resident Flash File For Part". 8. Is the software part number 05172187AC (or later)? a. If YES >>> then STOP. This bulletin does not apply. Further diagnosis is required. b. If NO >>> then perform the Repair Procedure. NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the CCN in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash CCN" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Customer Interest for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 14623 13. Highlight the listed calibration. 14. Select "Update Controller". Follow on screen instructions. 15. When the CCN update is complete, select "OK". 16. Verify the part number at the top of the "Flash CCN" screen has updated to the new part number. NOTE: Due to the CCN programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood Hood Sensor/Switch (For Alarm): All Technical Service Bulletins Antitheft System - Goes Off When Opening The Hood NUMBER: 08-040-06 GROUP: Electrical DATE: September 06, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: Vehicle Theft Security System Alarm May Alert When Hood Is Opened OVERVIEW: This bulletin involves selectively erasing and reprogramming the Cabin Compartment Node Module (CCN) with new software. MODELS: 2007 (DR/DH/D1/DC) Ram Truck NOTE: This bulletin applies to vehicles equipped with a remote start system (sales code XBM) prior to October 10, 2006 (MDH 1010XX). SYMPTOM/CONDITION: The Vehicle Theft Security System (VTSS) may alert (flash lights and/or sound horn) if one of the following occurs: a. The customer arms the VTSS and then reaches through an open window, pulls on the hood release, and fully opens the vehicle hood. b. The customer releases the hood but not enough to open the hood ajar switch, arms the VTSS, and then fully opens the vehicle hood. c. The customer opens the hood, arms the VTSS, the vehicle communications bus goes in to "sleep mode" (may take 10 minutes), then the "LOCK" button on the key fob is depressed. The hood ajar switch is not part of the VTSS used on domestic use vehicles. The hood ajar switch is used for export vehicles equipped with the Vehicle Theft Alarm (VTA) system. DIAGNOSIS: 1. Connect the StarSCAN(R) to the vehicle. 2. Power up the StarSCAN(R) and obtain the HOME menu. 3. From the HOME menu select "ECU VIEW". 4. Select "CCN - Cabin Compartment". 5. Select "More Options". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 14629 6. Select "ECU Flash" 7. Read and record the software part number that is display with "Resident Flash File For Part". 8. Is the software part number 05172187AC (or later)? a. If YES >>> then STOP. This bulletin does not apply. Further diagnosis is required. b. If NO >>> then perform the Repair Procedure. NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the CCN in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash CCN" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 14630 13. Highlight the listed calibration. 14. Select "Update Controller". Follow on screen instructions. 15. When the CCN update is complete, select "OK". 16. Verify the part number at the top of the "Flash CCN" screen has updated to the new part number. NOTE: Due to the CCN programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 14631 Hood Sensor/Switch (For Alarm): Locations Component ID: 469 Component : SWITCH-HOOD AJAR Connector: Name : SWITCH-HOOD AJAR Color : # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 HOOD AJAR SWITCH SENSE G70 20VT/LB 2 AAT RETURN G930 20VT/TN Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 14632 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 14633 Hood Sensor/Switch (For Alarm): Diagrams Component ID: 469 Component : SWITCH-HOOD AJAR Connector: Name : SWITCH-HOOD AJAR Color : # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 HOOD AJAR SWITCH SENSE G70 20VT/LB 2 AAT RETURN G930 20VT/TN Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 14634 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Description Hood Sensor/Switch (For Alarm): Description and Operation Description DESCRIPTION The hood ajar switch is a normally closed, single pole, spring-loaded plunger actuated switch. This switch has two unique versions that are used in two different applications. One switch is used only on vehicles equipped with the Vehicle Theft Alarm (VTA) system for sale in certain export markets where protection of the underhood area is required equipment. The second switch is used only on domestic vehicles equipped with an optional remote starter system. The molded plastic switch body (5) has an integral molded connector receptacle (1) on the lower end containing two terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the headlamp and dash wire harness. Two integral latches (2) lock the switch into a keyed mounting hole in the stamped steel switch mounting bracket. The mounting bracket is secured with screws to the inboard side of the right front fender load beam within the engine compartment. A molded plastic striker secured to the underside of the hood panel inner reinforcement actuates the switch plunger as the hood panel is closed. The switch plunger (3) extends through a mounting collar (4) and a sleeve-like retainer ring on the upper end of the switch body. The retainer ring has a one time, self-adjustment feature that is activated after the switch is installed by closing the hood. The retainer ring is also color-coded to aid in identifying the switch application. A dark brown retainer ring identifies the underhood security switch application, while a white retainer ring identifies the remote starter system application. An installed hood ajar switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or requires readjustment, it must be replaced with a new unit. The hood ajar switch striker is not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced with a new unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Description > Page 14637 Hood Sensor/Switch (For Alarm): Description and Operation Operation OPERATION The hood ajar switches are interchangeable physically, but not functionally. In each case, the hood ajar switch is a normally closed switch that is held open as the spring-loaded switch plunger is depressed by the striker on the inner hood panel reinforcement when the hood panel is closed and latched. When the hood is opened, the spring-loaded switch plunger extends from the switch body and the switch contacts are closed. In the underhood security application (export vehicles only - dark brown retainer ring), the switch is connected in series between ground and the hood ajar switch sense input of the Totally Integrated Power Module (TIPM). The TIPM uses an internal resistor pull up to monitor the state of the hood ajar switch contacts. In the remote starter system application (domestic vehicles only - white retainer ring) the switch has a 1 kilo ohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between an output of the TIPM and the hood ajar switch sense input of the TIPM. The TIPM continually monitors this circuit and will store a Diagnostic Trouble Code (DTC) for any fault that it detects. The components of the switch self-adjustment feature include an integral stop on the shaft of the plunger and a ribbed, ratcheting sleeve-like retainer ring at the top of the switch body from which the plunger extends. With the switch mounting collar secured in its mounting bracket, the plunger is depressed by the striker on the hood inner reinforcement as the hood is closed. As the plunger is depressed, the plunger stop contacts the top of the retainer ring and it is driven downward, ratcheting through the switch mounting collar until the hood is fully closed and latched. The ribs on the retainer ring are engaged within the mounting collar to maintain this adjusted position. The hood ajar switch as well as the hard wired circuits between the switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between modules and other devices related to hood ajar switch operation that provide some features of the export vehicle theft or domestic remote starter systems. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to hood ajar switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal Hood Sensor/Switch (For Alarm): Service and Repair Removal Striker STRIKER NOTE: The hood ajar switch striker is not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Unlatch and open the hood. 2. Using a trim stick or another suitable wide flat-bladed tool, pry the rearward end of the hood ajar switch striker (2) away from the inner hood panel reinforcement (1) far enough to disengage the integral retainers from their mounting holes. 3. Remove the striker from the inner hood panel reinforcement and discard. Bracket BRACKET 1. Remove the hood ajar switch (2) from the mounting bracket (3). 2. Remove the two screws (4) that secure the hood ajar switch bracket to the two rivet nuts (1) in the right front load beam (6). 3. Remove the hood ajar switch mounting bracket from the inboard side of the right front load beam. Switch SWITCH Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal > Page 14640 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. From the top of the mounting bracket (3) on the right front load beam (6), squeeze the two hood ajar switch (2) latch tabs together and pull the switch upward. 4. Pull the hood ajar switch up through the hole in the mounting bracket far enough to access and disconnect the jumper wire harness connector (5) from the switch connector receptacle. 5. Remove the hood ajar switch from the mounting bracket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal > Page 14641 Hood Sensor/Switch (For Alarm): Service and Repair Installation Striker STRIKER NOTE: The hood ajar switch striker cap is not intended for reuse. If the striker cap is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Position the new hood ajar switch striker (2) to the mounting holes in the inner hood panel reinforcement (1) over the hood ajar switch (3). 2. Using hand pressure, press the hood ajar switch striker upward into the mounting holes in the inner hood panel reinforcement until both integral retainers are fully engaged. 3. Close and latch the hood. Bracket BRACKET 1. Check to be certain that the two rivet nuts (1) on the inboard side of the right front load beam (6) are in good condition and properly secured. 2. Position the hood ajar switch mounting bracket (3) onto the right front load beam. 3. Install and tighten the two screws (4) that secure the mounting bracket to the load beam. Beginning with the rearward screw, tighten both screws to 8 Nm (71 in. lbs.). 4. Reinstall the hood ajar switch (2) into the mounting bracket. Switch Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal > Page 14642 SWITCH 1. Position the hood ajar switch (2) near the hole in the mounting bracket (3) on the right front load beam (6). 2. Route the jumper wire harness connector (5) through the switch mounting bracket and reconnect it to the switch connector receptacle. 3. From the top of the mounting bracket, press the switch downward into the mounting hole until the integral switch latch tabs lock it into place. 4. Reconnect the battery negative cable. 5. Close and latch the hood. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Component ID: 457 Component : SWITCH-ADJUSTABLE PEDALS Connector: Name : SWITCH-ADJUSTABLE PEDALS Color : BLUE # of pins : 6 Qualifier : (EXCEPT BASE) Pin Description Circuit 1 ADJUSTABLE PEDALS MOTOR REARWARDP206 18LG/LB 2 ADJUSTABLE PEDALS OUTPUT A72 18RD/OR 3-4 GROUND Z146 18BK 5 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 6 ADJUSTABLE PEDALS MOTOR FORWARD P205 18LG/WT Component Location - 44 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 14646 Component Location - 50 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 14647 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 14648 Pedal Positioning Switch: Diagrams Component ID: 457 Component : SWITCH-ADJUSTABLE PEDALS Connector: Name : SWITCH-ADJUSTABLE PEDALS Color : BLUE # of pins : 6 Qualifier : (EXCEPT BASE) Pin Description Circuit 1 ADJUSTABLE PEDALS MOTOR REARWARDP206 18LG/LB 2 ADJUSTABLE PEDALS OUTPUT A72 18RD/OR 3-4 GROUND Z146 18BK 5 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 6 ADJUSTABLE PEDALS MOTOR FORWARD P205 18LG/WT Component Location - 44 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 14649 Component Location - 50 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 14650 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Service and Repair > Removal Pedal Positioning Switch: Service and Repair Removal REMOVAL 1. Remove the lower drivers side bezel (4). 2. Disconnect the electrical connector (3) from the adjustable pedal switch (2). 3. Remove the switch (2) from the lower drivers side bezel (4) by squeezing the retaining clips together and pushing the switch outwards. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Service and Repair > Removal > Page 14653 Pedal Positioning Switch: Service and Repair Installation INSTALLATION 1. Install the switch (2) to the lower drivers side bezel (4) by pushing the switch inwards seating the retaining clips to the lower drivers side bezel (4). 2. Reconnect the electrical connector (3) to the adjustable pedal switch (2). 3. Install the lower drivers side bezel (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Description Remote Switch: Description and Operation Description DESCRIPTION Two rocker-type switches (if equipped) are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player, CD player or CD changer (if equipped). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Description > Page 14658 Remote Switch: Description and Operation Operation OPERATION The six switches in the two remote radio switch units are normally open, resistor multiplexed momentary switches that are hard wired to the Totally Integrated Power Module (TIPM) through the clockspring. The TIPM sends a five volt reference signal to both switch units on one circuit, and senses the status of all of the switches by reading the voltage drop on a second circuit. When the TIPM senses an input (voltage drop) from any one of the remote radio switches, it sends the proper switch status messages on the Programmable Communication Interface (PCI) data bus network to the radio receiver. The electronic circuitry within the radio receiver is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. For diagnosis of the TIPM or the PCI data bus, the use of a scan tool and the proper Diagnostic Procedures information is recommended. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 14659 Remote Switch: Testing and Inspection REMOTE SWITCHES Any diagnosis of the Audio system should begin with the use of scan tool. For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the remote radio switch(es) from the steering wheel. 3. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test chart. If the remote radio switch resistances check OK, go to STEP 4. If not OK, replace the faulty switch. 4. Connect the battery negative cable. Turn the ignition switch to the On position. Check for 5 volts at the radio control mux circuit cavities of the steering wheel wire harness connectors for both remote radio switches. If OK, go to STEP 5. If not OK, repair the open or shorted radio control mux circuit to the Totally Integrated Power Module (TIPM) as required. 5. Disconnect and isolate the battery negative cable. Disconnect the 22-way instrument panel wire harness connector from the TIPM. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and a good ground. There should be no continuity. If OK, go to STEP 6. If not OK, repair the shorted remote radio switch ground circuit to the TIPM as required. 6. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and the 22-way instrument panel wire harness connector for the TIPM. There should be continuity. If OK, refer to the proper Diagnostic Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 14660 Procedures to test the TIPM and the PCI data bus. If not OK, repair the open remote radio switch ground circuit as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Removal Remote Switch: Service and Repair Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag. 3. Remove the speed control switches (2). 4. Unplug the wire harness connector from the remote radio switch (1). 5. Depress the tabs on each side of each switch and push the switch through the rear steering wheel cover. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Removal > Page 14663 Remote Switch: Service and Repair Installation INSTALLATION WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Install remote radio switch (1) to the steering wheel. 2. Connect the wire harness to the remote radio switch. 3. Install the speed control switches (2). 4. Install the driver airbag. 5. Connect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations Steering Mounted Controls Communication Module: Locations Component ID: 212 Component : MODULE-STEERING CONTROL Connector: Name : MODULE-STEERING CONTROL C1 Color : WHITE # of pins : 6 Pin Description Circuit 1 GROUND Z909 20BK 2 RADIO CONTROL MUX X20 20GY/WT 3 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 4 S/C SWITCH NO. 1 SIGNAL V37 20VT 5 S/C SWITCH RETURN V937 20VT/BR 6 HORN SWITCH SENSE X3 20DG/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 14667 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 14668 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 14669 Connector: Name : MODULE-STEERING CONTROL C2 Color : BLACK # of pins : 2 Qualifier : (PREMIUM) Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 14670 2 RADIO CONTROL MUX X20 22GY/WT 2 RADIO CONTROL MUX X20 22GY/WT Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 14671 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 14672 Connector: Name : MODULE-STEERING CONTROL C3 Color : # of pins : 4 Pin Description Circuit 1 HORN SWITCH SENSE X3 20DG/VT 2 S/C SWITCH RETURN V937 22DB/DG 2 SENSOR GROUND K900 22DB/DG 3 S/C SWITCH NO. 1 SIGNAL V37 22VT 4 S/C SWITCH NO. 2 SIGNAL V38 22VT/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 14673 Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 14674 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 14675 Connector: Name : MODULE-STEERING CONTROL C4 Color : YELLOW # of pins : 4 Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R61 20LG/VT 2 DRIVER SQUIB 2 LINE 2 R63 20LG/WT 3 DRIVER SQUIB 1 LINE 1 R43 20LG/BR 4 DRIVER SQUIB 1 LINE 2 R45 20LG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 14676 Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 14677 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 14678 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 14679 Steering Mounted Controls Communication Module: Diagrams Component ID: 212 Component : MODULE-STEERING CONTROL Connector: Name : MODULE-STEERING CONTROL C1 Color : WHITE # of pins : 6 Pin Description Circuit 1 GROUND Z909 20BK 2 RADIO CONTROL MUX X20 20GY/WT 3 S/C SWITCH NO. 2 SIGNAL V38 20VT/OR 4 S/C SWITCH NO. 1 SIGNAL V37 20VT 5 S/C SWITCH RETURN V937 20VT/BR 6 HORN SWITCH SENSE X3 20DG/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 14680 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 14681 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 14682 Connector: Name : MODULE-STEERING CONTROL C2 Color : BLACK # of pins : 2 Qualifier : (PREMIUM) Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Pin Description Circuit 1 SWITCH MUX RETURN G902 22WT/BR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 14683 2 RADIO CONTROL MUX X20 22GY/WT 2 RADIO CONTROL MUX X20 22GY/WT Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 14684 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 14685 Connector: Name : MODULE-STEERING CONTROL C3 Color : # of pins : 4 Pin Description Circuit 1 HORN SWITCH SENSE X3 20DG/VT 2 S/C SWITCH RETURN V937 22DB/DG 2 SENSOR GROUND K900 22DB/DG 3 S/C SWITCH NO. 1 SIGNAL V37 22VT 4 S/C SWITCH NO. 2 SIGNAL V38 22VT/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 14686 Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 14687 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 14688 Connector: Name : MODULE-STEERING CONTROL C4 Color : YELLOW # of pins : 4 Pin Description Circuit 1 DRIVER SQUIB 2 LINE 1 R61 20LG/VT 2 DRIVER SQUIB 2 LINE 2 R63 20LG/WT 3 DRIVER SQUIB 1 LINE 1 R43 20LG/BR 4 DRIVER SQUIB 1 LINE 2 R45 20LG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 14689 Component Location - 47 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 14690 Component Location - 43 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 14691 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Hook / Bracket > Component Information > Service and Repair > Removal Towing Hook / Bracket: Service and Repair Removal REMOVAL 1. Remove front bumper. 2. Remove the bolts (2) and remove the tow hook assembly (3). 3. If the vehicle is a Heavy Duty, then remove the bolts (1) and remove the tow hook (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Hook / Bracket > Component Information > Service and Repair > Removal > Page 14697 Towing Hook / Bracket: Service and Repair Installation INSTALLATION 1. Install the tow hook assembly (3) and bolts (2) hand tight. 2. If vehicle is a Heavy Duty, install the tow hook (2) and bolts (1) hand tight. 3. Install the front bumper. 4. Line up the tow hooks/tow hook assembly and tighten the bolts to 68 Nm (50 ft. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Locations Trailer Brake Control Module: Locations Component ID: 201 Component : MODULE-BRAKE PROVISION Connector: Name : MODULE-BRAKE PROVISION Color : BLUE # of pins : 4 Pin Description Circuit 1 GROUND Z998 18BK 2 BRAKE LAMP SWITCH OUTPUT L50 18WT/TN 3 TRAILER TOW BRAKE B(+) B40 14DG 4 FUSED B(+) A400 14TN/RD Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Locations > Page 14701 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Locations > Page 14702 Trailer Brake Control Module: Diagrams Component ID: 201 Component : MODULE-BRAKE PROVISION Connector: Name : MODULE-BRAKE PROVISION Color : BLUE # of pins : 4 Pin Description Circuit 1 GROUND Z998 18BK 2 BRAKE LAMP SWITCH OUTPUT L50 18WT/TN 3 TRAILER TOW BRAKE B(+) B40 14DG 4 FUSED B(+) A400 14TN/RD Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Locations > Page 14703 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Wiring-Trailer Tow Trailer Connector: Locations Wiring-Trailer Tow Component ID: 499 Component : WIRING-TRAILER TOW Connector: Name : WIRING-TRAILER TOW Color : # of pins : 1 Qualifier : (BOX OFF) Pin Description Circuit 1 FUSED B(+) A100 14RD/VT Pin Description Circuit 1 TRAILER TOW BRAKE B(+) B40 14DG Pin Description Circuit 1 BACKUP LAMP FEED L1 18WT/LG Pin Description Circuit 1 TRAILER TOW LEFT TURN RELAY OUTPUTL673 18YL Pin Description Circuit 1 TRAILER TOW RIGHT TURN RELAY OUTPUT L674 18LG Pin Description Circuit 1 FUSED PARK LAMP FEED L678 18BR Pin Description Circuit 1 GROUND Z927 14BK Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Wiring-Trailer Tow > Page 14708 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Wiring-Trailer Tow > Page 14709 Trailer Connector: Locations Wiring-Trailer Tow 4-Way Component ID: 500 Component : WIRING-TRAILER TOW 4-WAY Connector: Name : WIRING-TRAILER TOW 4-WAY Color : BLACK # of pins : 4 Pin Description Circuit 1 GROUND Z927 14BK 2 FUSED PARK LAMP FEED L678 18BR 3 TRAILER TOW LEFT TURN RELAY OUTPUTL673 18YL 4 TRAILER TOW RIGHT TURN RELAY OUTPUT L674 18LG Component Location - 69 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Wiring-Trailer Tow > Page 14710 Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Wiring-Trailer Tow > Page 14711 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Wiring-Trailer Tow > Page 14712 Trailer Connector: Locations Wiring-Trailer Tow 7-Way Component ID: 501 Component : WIRING-TRAILER TOW 7-WAY Connector: Name : WIRING-TRAILER TOW 7-WAY Color : BLACK # of pins : 10 Pin Description Circuit 1-2 TRAILER TOW RIGHT TURN RELAY OUTPUT L674 18LG 3 BACKUP LAMP FEED L1 18WT/LG 4 FUSED B(+) A100 14RD/VT 5 FUSED PARK LAMP FEED L678 18BR 6-7 TRAILER TOW BRAKE B(+) B40 14DG 8 GROUND Z927 14BK 9 GROUND Z927 14BK 10 TRAILER TOW LEFT TURN RELAY OUTPUTL673 18YL Component Location - 69 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Wiring-Trailer Tow > Page 14713 Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Wiring-Trailer Tow > Page 14714 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14717 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14718 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14719 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14720 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14721 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14722 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14723 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14724 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14725 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14726 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14727 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14728 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14729 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14730 Trailer Connector: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14731 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14732 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14733 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14734 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14735 Trailer Connector: Connector Views Wiring-Trailer Tow Component ID: 499 Component : WIRING-TRAILER TOW Connector: Name : WIRING-TRAILER TOW Color : # of pins : 1 Qualifier : (BOX OFF) Pin Description Circuit 1 FUSED B(+) A100 14RD/VT Pin Description Circuit 1 TRAILER TOW BRAKE B(+) B40 14DG Pin Description Circuit 1 BACKUP LAMP FEED L1 18WT/LG Pin Description Circuit 1 TRAILER TOW LEFT TURN RELAY OUTPUTL673 18YL Pin Description Circuit 1 TRAILER TOW RIGHT TURN RELAY OUTPUT L674 18LG Pin Description Circuit 1 FUSED PARK LAMP FEED L678 18BR Pin Description Circuit 1 GROUND Z927 14BK Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14736 Wiring-Trailer Tow 4-Way Component ID: 500 Component : WIRING-TRAILER TOW 4-WAY Connector: Name : WIRING-TRAILER TOW 4-WAY Color : BLACK # of pins : 4 Pin Description Circuit Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14737 1 GROUND Z927 14BK 2 FUSED PARK LAMP FEED L678 18BR 3 TRAILER TOW LEFT TURN RELAY OUTPUTL673 18YL 4 TRAILER TOW RIGHT TURN RELAY OUTPUT L674 18LG Component Location - 69 Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14738 Wiring-Trailer Tow 7-Way Component ID: 501 Component : WIRING-TRAILER TOW 7-WAY Connector: Name : WIRING-TRAILER TOW 7-WAY Color : BLACK # of pins : 10 Pin Description Circuit Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14739 1-2 TRAILER TOW RIGHT TURN RELAY OUTPUT L674 18LG 3 BACKUP LAMP FEED L1 18WT/LG 4 FUSED B(+) A100 14RD/VT 5 FUSED PARK LAMP FEED L678 18BR 6-7 TRAILER TOW BRAKE B(+) B40 14DG 8 GROUND Z927 14BK 9 GROUND Z927 14BK 10 TRAILER TOW LEFT TURN RELAY OUTPUTL673 18YL Component Location - 69 Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14740 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14741 Trailer Connector: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-54-02 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14742 8w-54-03 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14743 8w-54-04 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14744 8w-54-05 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14745 8w-54-06 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Service and Repair > Removal Trailer Connector: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Reach behind the center of the rear bumper to access and disconnect the connector (2) of the body wire harness from the 7-way trailer tow connector (1). 3. Remove the four screws (3) that secure the 7-way trailer tow connector (2) to the tapping plate (4) behind the rear bumper. 4. Remove the 7-way trailer tow connector from the face of the rear bumper and the tapping plate from behind the rear bumper. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Service and Repair > Removal > Page 14748 Trailer Connector: Service and Repair Installation INSTALLATION 1. Position the 7-way trailer tow connector (2) into the mounting hole on the face of the rear bumper (1). 2. Position the tapping plate (4) over the 7-way trailer tow connector on the back of the rear bumper. 3. Install and tighten the four screws (3) that secure the 7-way trailer tow connector to the tapping plate. Tighten the screws to 2 Nm (17 in. lbs.). 4. Reach behind the center of the rear bumper to access and reconnect the connector (2) of the body wire harness to the 7-way trailer tow connector (1). 5. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Removal Trailer Hitch: Service and Repair Removal REMOVAL 1. Remove the rear bumper. 2. On Light Duty Vehicles, remove the hitch bolts (7) 3. On Heavy Duty Vehicles, remove the hitch bolts (8) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Removal > Page 14753 4. Disconnect all wire harness support push pins. 5. Remove the rear two cargo box bolts (3) and loosen the remaining bolts. 6. Using a suitable lifting device, lift and support the rear of the cargo box and remove the hitch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Removal > Page 14754 Trailer Hitch: Service and Repair Installation INSTALLATION 1. On Light Duty Vehicles, install the hitch (5) onto the frame rails and make sure the locators (1 and 2) on the inside of the hitch brackets are engaged with the holes in the top of the frame rails properly. 2. Install the hitch bolts (7) and tighten to 170 Nm (125 ft. lbs.). 3. Connect all wire harness support push pins. 4. On Heavy Duty Vehicles, install the hitch (5) onto the frame rails and make sure the locators (1 and 2) on the inside of the hitch brackets are engaged with the holes in the top of the frame rails properly. 5. Install the hitch bolts (8) and tighten to 170 Nm (125 ft. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Removal > Page 14755 6. Connect all wire harness support push pins. 7. Lower the cargo box and install the rear bolts (3). 8. Install the rear bumper. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 14760 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 14761 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 14762 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 14763 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 14764 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 14765 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 14766 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 14767 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 14768 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 14769 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 14770 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 14771 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 14772 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 14773 Trailer Lamps: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 14774 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 14775 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 14776 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 14777 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Description and Operation > Description Trailer Lamps: Description and Operation Description DESCRIPTION The rear body wire harness on the rear frame (1) of all vehicles is equipped with a take out with a standard, light-duty 4-pin trailer tow connector (2) that is secured to the top of the trailer hitch platform (4) behind the rear bumper. Vehicles equipped with an optional factory-installed trailer towing package have a second take out with a connector (3) that plugs into a receptacle in the back of a heavy duty, sealed, 7-pin trailer tow connector that is located near the center of the rear bumper. Vehicles equipped with the trailer tow package also include an electric trailer brake wiring provision that terminates at a connector located on top of the large body harness connection under the instrument panel to the left of the brake pedal, as well as an electric trailer brake pigtail harness and an instruction card (1) that are stored in the glove box (2) when the vehicle is shipped from the factory. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Description and Operation > Description > Page 14780 Trailer Lamps: Description and Operation Operation OPERATION The standard 4-pin trailer tow connector contains the following vehicle circuits: park/tail lamps, left stop/turn lamp, right stop/turn lamp, and ground. The optional trailer towing package 7-way connector contains the same circuits as the 4-pin connector plus the following additional circuits: backup lamp, trailer battery and electric brake. If an aftermarket electric brake controller is used, the electric brake pigtail harness supplied will make installation easier. The connection (blue 4-way connector) for the harness is located under the instrument panel to the left of the brake pedal on top of the large body harness connection. Refer to the appropriate wiring information. The battery line of this harness may be used to charge the trailer battery. However, a battery isolation unit is not supplied and the trailer battery may discharge the vehicle battery while the engine is not running. The battery line is protected by a fuse or a circuit breaker. Refer to the owner's manual in the vehicle glove box for type, location, and ampere rating of the fuse or circuit breaker. The trailer tow connectors as well as the hard wired inputs and outputs of the connectors may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Dodge Ram Trucks, 2006-2009 all,Trailer Tow lamp relay is not serviceable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 14784 Trailer Lighting Relay: Diagrams Dodge Ram Trucks, 2006-2009 all, do not use a trailer tow relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Wiring-Trailer Tow Trailer Connector: Locations Wiring-Trailer Tow Component ID: 499 Component : WIRING-TRAILER TOW Connector: Name : WIRING-TRAILER TOW Color : # of pins : 1 Qualifier : (BOX OFF) Pin Description Circuit 1 FUSED B(+) A100 14RD/VT Pin Description Circuit 1 TRAILER TOW BRAKE B(+) B40 14DG Pin Description Circuit 1 BACKUP LAMP FEED L1 18WT/LG Pin Description Circuit 1 TRAILER TOW LEFT TURN RELAY OUTPUTL673 18YL Pin Description Circuit 1 TRAILER TOW RIGHT TURN RELAY OUTPUT L674 18LG Pin Description Circuit 1 FUSED PARK LAMP FEED L678 18BR Pin Description Circuit 1 GROUND Z927 14BK Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Wiring-Trailer Tow > Page 14789 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Wiring-Trailer Tow > Page 14790 Trailer Connector: Locations Wiring-Trailer Tow 4-Way Component ID: 500 Component : WIRING-TRAILER TOW 4-WAY Connector: Name : WIRING-TRAILER TOW 4-WAY Color : BLACK # of pins : 4 Pin Description Circuit 1 GROUND Z927 14BK 2 FUSED PARK LAMP FEED L678 18BR 3 TRAILER TOW LEFT TURN RELAY OUTPUTL673 18YL 4 TRAILER TOW RIGHT TURN RELAY OUTPUT L674 18LG Component Location - 69 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Wiring-Trailer Tow > Page 14791 Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Wiring-Trailer Tow > Page 14792 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Wiring-Trailer Tow > Page 14793 Trailer Connector: Locations Wiring-Trailer Tow 7-Way Component ID: 501 Component : WIRING-TRAILER TOW 7-WAY Connector: Name : WIRING-TRAILER TOW 7-WAY Color : BLACK # of pins : 10 Pin Description Circuit 1-2 TRAILER TOW RIGHT TURN RELAY OUTPUT L674 18LG 3 BACKUP LAMP FEED L1 18WT/LG 4 FUSED B(+) A100 14RD/VT 5 FUSED PARK LAMP FEED L678 18BR 6-7 TRAILER TOW BRAKE B(+) B40 14DG 8 GROUND Z927 14BK 9 GROUND Z927 14BK 10 TRAILER TOW LEFT TURN RELAY OUTPUTL673 18YL Component Location - 69 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Wiring-Trailer Tow > Page 14794 Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Wiring-Trailer Tow > Page 14795 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14798 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14799 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14800 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14801 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14802 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14803 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14804 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14805 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14806 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14807 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14808 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14809 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14810 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14811 Trailer Connector: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14812 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14813 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14814 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14815 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14816 Trailer Connector: Connector Views Wiring-Trailer Tow Component ID: 499 Component : WIRING-TRAILER TOW Connector: Name : WIRING-TRAILER TOW Color : # of pins : 1 Qualifier : (BOX OFF) Pin Description Circuit 1 FUSED B(+) A100 14RD/VT Pin Description Circuit 1 TRAILER TOW BRAKE B(+) B40 14DG Pin Description Circuit 1 BACKUP LAMP FEED L1 18WT/LG Pin Description Circuit 1 TRAILER TOW LEFT TURN RELAY OUTPUTL673 18YL Pin Description Circuit 1 TRAILER TOW RIGHT TURN RELAY OUTPUT L674 18LG Pin Description Circuit 1 FUSED PARK LAMP FEED L678 18BR Pin Description Circuit 1 GROUND Z927 14BK Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14817 Wiring-Trailer Tow 4-Way Component ID: 500 Component : WIRING-TRAILER TOW 4-WAY Connector: Name : WIRING-TRAILER TOW 4-WAY Color : BLACK # of pins : 4 Pin Description Circuit Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14818 1 GROUND Z927 14BK 2 FUSED PARK LAMP FEED L678 18BR 3 TRAILER TOW LEFT TURN RELAY OUTPUTL673 18YL 4 TRAILER TOW RIGHT TURN RELAY OUTPUT L674 18LG Component Location - 69 Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14819 Wiring-Trailer Tow 7-Way Component ID: 501 Component : WIRING-TRAILER TOW 7-WAY Connector: Name : WIRING-TRAILER TOW 7-WAY Color : BLACK # of pins : 10 Pin Description Circuit Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14820 1-2 TRAILER TOW RIGHT TURN RELAY OUTPUT L674 18LG 3 BACKUP LAMP FEED L1 18WT/LG 4 FUSED B(+) A100 14RD/VT 5 FUSED PARK LAMP FEED L678 18BR 6-7 TRAILER TOW BRAKE B(+) B40 14DG 8 GROUND Z927 14BK 9 GROUND Z927 14BK 10 TRAILER TOW LEFT TURN RELAY OUTPUTL673 18YL Component Location - 69 Component Location - 70 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14821 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14822 Trailer Connector: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-54-02 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14823 8w-54-03 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14824 8w-54-04 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14825 8w-54-05 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 14826 8w-54-06 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Service and Repair > Removal Trailer Connector: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Reach behind the center of the rear bumper to access and disconnect the connector (2) of the body wire harness from the 7-way trailer tow connector (1). 3. Remove the four screws (3) that secure the 7-way trailer tow connector (2) to the tapping plate (4) behind the rear bumper. 4. Remove the 7-way trailer tow connector from the face of the rear bumper and the tapping plate from behind the rear bumper. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Service and Repair > Removal > Page 14829 Trailer Connector: Service and Repair Installation INSTALLATION 1. Position the 7-way trailer tow connector (2) into the mounting hole on the face of the rear bumper (1). 2. Position the tapping plate (4) over the 7-way trailer tow connector on the back of the rear bumper. 3. Install and tighten the four screws (3) that secure the 7-way trailer tow connector to the tapping plate. Tighten the screws to 2 Nm (17 in. lbs.). 4. Reach behind the center of the rear bumper to access and reconnect the connector (2) of the body wire harness to the 7-way trailer tow connector (1). 5. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Description and Operation > Description Trip Computer: Description and Operation Description DESCRIPTION NOTE: The Compass Mini-Trip Computer (CMTC) module is sometimes referred to as Electronic Overhead Module (EOM) for the purposes of scan tool and diagnostic information naming. Please treat the CMTC and EOM as one and the same when diagnosing the vehicle. The Compass Mini-Trip Computer (CMTC) is located in the overhead console and consists of the following components: - HomeLink(R) transceiver (3) - if equipped - Vacuum-Fluorescent Display (VFD) (6) - Push button function switches (1, 2, 3, 4 and 5) - Replaceable light bulbs to illuminate the push button function switches The CMTC contains a central processing unit and interfaces with other electronic modules in the vehicle on the Controller Area Network (CAN) data bus. The CAN data bus allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The individual components of the CMTC module are not serviced separately and if damaged or inoperative, must be replaced as a unit. The CMTC provides several electronic functions and features. Some of the functions and features that the CMTC supports and/or controls, include the following display options: - Compass and Temperature - provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. - Trip Odometer (ODO) - shows the distance travelled since the last trip computer reset. Average Fuel Economy (AVG ECO) - shows the average fuel economy since the last reset. Average fuel economy is a running average of the amount of fuel used and the distance the vehicle has traveled. When the fuel economy is reset, the display will momentarily blank. Then, the display will show the same value as before the rest. The reset value is based on a minimal amount of fuel used and the distance traveled from the previous drive cycle. The display may take several miles for this value to change dependent upon driving habits. - Distance To Empty (DTE) - shows the estimated distance that can be traveled with the fuel remaining in the tank. This estimated distance is determined by weighted average of the instantaneous and average fuel economy, according to the current fuel tank level. This is not resettable. Significant changes in driving style or vehicle loading will greatly affect the actual drivable distance of the vehicle, regardless of the DTE displayed value. When the DTE value is less than 30 miles estimated driving distance, the DTE display will change to an alternating test display of "LO" and "FUEL". This display will continue until the vehicle runs out of fuel. Adding a significant amount of fuel to the vehicle will turn off the "LO FUEL" text and a new DTE value will be displayed, based on the current values in the DTE calculation and the current fuel tank level. - Elapsed time (ET) - shows the accumulated ignition-on time since the last trip computer reset. - Blank screen - the compass mini-trip computer VFD is turned off or in Blank Screen Mode. COMPASS NOTE: If the compass functions, but accuracy is suspect, it may be necessary to perform a variance adjustment. This procedure allows the compass unit to accommodate variances in the earth's magnetic field strength, based on geographic location. While in the compass/temperature mode, the compass will display the direction in which the vehicle is pointed using the eight major compass headings (Examples: north is N, northeast is NE). The auto-calibrating compass unit requires no manual adjusting in normal use. The only calibration that may prove necessary is to drive the vehicle in one or two complete circles, on level ground, not exceeding 8 km/h (5 mph). This will reorient the compass unit to its vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Description and Operation > Description > Page 14834 The compass unit also will compensate for vehicle magnetism acquired during normal use. However, avoid placing anything magnetic directly on the roof of the vehicle. Magnetic mounts for an antenna, a repair order hat, or a funeral procession flag can exceed the compensating ability of the compass unit if placed on the roof panel. Magnetic bit drivers used on the fasteners that hold the overhead console assembly to the roof header can also affect compass operation. TEMPERATURE NOTE: The displayed temperature is not an instant reading of conditions, but an average temperature. It may take the temperature display several minutes to respond to a major temperature change, such as driving out of a heated garage into winter temperatures. The temperature displays the outside ambient temperature in whole degrees. The temperature display can be toggled from Fahrenheit to Celsius using the U.S./Metric push button. Displayed temperature reading stays in the temperature unit memory. When the ignition switch is turned to the On position, the temperature will display the memory temperature if the engine OFF time is less than 255 minutes. If the engine OFF time is more than 255 minutes, the temperature will display the actual temperature sensed by the ambient temperature sensor. The temperature display update interval varies with the vehicle speed. The temperature function is supported by an ambient temperature sensor. This sensor is mounted outside the passenger compartment near the front and center of the vehicle, and is hard wired to the Front Control Module (FCM). The instrument cluster, also known as the Cab Compartment Node (CCN) averages and filters the ambient temperature signal and supplies it to other modules on the CAN data bus. Data input for all other compass mini-trip computer functions, including VFD dimming level, is received through CAN data bus messages. The maximum temperature displayed is 66° C (140° F). It could take several miles for the accurate temperature to be displayed as the CCN filters out heat from the engine compartment. The CMTC uses its internal programming and all of these inputs to calculate and display the requested data. If the data displayed is incorrect, perform the self-diagnostic tests. If these tests prove inconclusive, the use of a scan tool and the proper Diagnostic Procedures Information are recommended for further testing of the CMTC and the CAN data bus. NOTE: The CMTC will display min and max temperatures of -40° C (-40° F) and 66° C (140° F). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Description and Operation > Description > Page 14835 Trip Computer: Description and Operation Operation OPERATION The Compass Mini-Trip Computer (CMTC) only operates with the ignition switch in the On position and the Ignition Off Draw (IOD) fuse functioning and in place. When the ignition switch is turned to the On position, all of the segments in the CMTC Vacuum-Fluorescent Display (VFD) will be turned off for one second, then the display will return to the last function being displayed before the ignition was turned to the Off position. With the ignition switch in the On position, momentarily depressing and releasing the STEP push button (4) will cause the CMTC to change its mode of operation. Momentarily depressing and releasing the U.S./M push button (1) will cause the unit to toggle between U.S. and Metric measurements. Momentarily depressing and releasing the C/T (compass/temperature) push button (5) will cause the CMTC to return to the compass/temperature display mode from any other mode. Pressing the RESET push button (2) for more than one second with the ignition switch in the On position will reset the following CMTC functions: - Average Fuel Economy (AVG ECO) - Trip Odometer (ODO) - Elapsed Time (ET) However, the reset will only occur if the function currently displayed is a function that can be reset. If the RESET push button is pressed twice within two seconds while in any of the three resettable functions (AVG ECO, ODO, ET), all three of these functions will be reset. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Description and Operation > Page 14836 Trip Computer: Testing and Inspection COMPASS MINI-TRIP COMPUTER NOTE: The temperature, fuel economy, distance to empty and trip odometer are calculated in the Cab Compartment Node (CCN) and transferred to the Compass Mini-Trip Computer (CMTC) for display. If the CMTC and Vacuum Fluorescent Display (VFD) test OK, testing of the CCN and Controller Area Network (CAN) data bus circuit may be necessary. Refer to the proper Diagnostic Procedures Information to test the CCN and CAN data bus circuit. If the problem with the CMTC is an inaccurate or scrambled display, refer to SELF- DIAGNOSTIC TEST. If the problem with the CMTC is incorrect Vacuum Fluorescent Display (VFD) dimming levels, use a scan tool and the proper Diagnostic Procedures Information to test for the correct dimming message inputs being received from the Cab Compartment Node (CCN) or Front Control Module (FCM) over the Controller Area Network (CAN) data bus circuit. If the problem is a no-display condition, use the following procedure. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the overhead console from the headliner. 2. Inspect the Ignition Off Draw (IOD) fuse in the Totally Integrated Power Module (TIPM). If the IOD fuse is OK and in place, go to STEP 3. If not OK, repair the open IOD fuse circuit as required. 3. Check for battery voltage at the overhead console electrical connector. If OK, go to STEP 4. If not OK, Check for battery voltage at the appropriate B(+) fuse in the Totally Integrated Power Module (TIPM), repair the open fused B(+) circuit as required. 4. Turn the ignition switch to the On position. Check the fused ignition switch output circuit(s) at the overhead console electrical connector. If OK, go to STEP 5. If not OK, repair the open or shorted circuit as required. 5. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Check for continuity between the ground circuit cavity of the overhead console electrical connector and a good ground. There should be continuity. If OK, refer to SELF- DIAGNOSTIC TEST for further diagnosis of the CMTC module and the CAN data bus circuit. If not OK, repair the open ground circuit as required. SELF- DIAGNOSTIC TEST NOTE: The CMTC self - test can also be performed using a scan tool. Navigate to the Auto Self Test screen under System Tests of the scan tool and initiate the CMTC self - test. A self-diagnostic test is used to determine that the CMTC is operating properly electrically. Initiate the self-diagnostic test as follows: 1. With the ignition switch in the Off position, simultaneously depress and hold the STEP and RESET buttons while rotating the ignition switch to the Run/On position. 2. Continue to hold both buttons depressed until the CMTC enters the display segment test. In this test, all of the Vacuum Fluorescent Display (VFD) segments are lighted while the CMTC performs the following checks: Non-Volatile Memory Status (NVM) - RAM Status - ROM Status - ASIC Communication Status - Compass Status - DC Status - CAN Data Bus Communications Status NOTE: If the CMTC module is equipped with the Universal Transmitter (also known as HomeLink(R)), the module also checks "HomeLink(R) Communication Test Status". 3. Following completion of these tests, the CMTC will display one of two messages: "FAIL" or "PASS." Press the RESET or STEP button to exit and enter normal mode. Respond to these test results as follows: If no test result message is displayed, but CMTC operation is still improper, the use of a scan tool and the proper Diagnostic Procedures Information are required for further diagnosis. - If the "FAIL" message is displayed, the CMTC is inoperative and must be replaced. - If the "PASS" message is displayed, the CMTC is OK, no faults are present. - If any VFD segment does not light during the display segment test, the CMTC is inoperative and must be replaced. If the first seven tests pass, the CMTC shall verify that all the required CAN bus messages are present on the CAN bus. If all required messages are Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Description and Operation > Page 14837 present on the CAN bus, the CMTC will automatically return to normal operation after sixty seconds. The CMTC can also be returned to normal operation any time during the test by pressing the STEP, CT, RESET or US/M buttons. NOTE: Pressing the STEP or RESET buttons during any portion of the CMTC Self - Diagnostic Test Procedure will cause the CMTC to exit diagnostics and return to compass/temperature mode. NOTE: If the compass functions, but accuracy is suspect, it may be necessary to perform a variance adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. NOTE: If the compass reading has blanked out, and only "CAL" appears in the display, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle. Check for stored Diagnostic Trouble Codes (DTCs) and follow the proper Diagnostic Procedures Information as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Adjustments > Manual Compass Calibration Trip Computer: Adjustments Manual Compass Calibration MANUAL COMPASS CALIBRATION CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the overhead console. Do not use magnetic tools when servicing the overhead console. NOTE: Whenever the compass is calibrated manually, the variance number must also be reset. The electronic compass unit features a self-calibrating design, which simplifies the calibration procedure. This feature automatically updates the compass calibration while the vehicle is being driven. This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use. If the compass readings appear to be erratic or out of calibration, perform the following calibration procedure. Also, new service replacement Compass Mini-Trip Computer (CMTC) modules must have their compass calibrated using this procedure. Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. Calibrate the compass manually as follows: 1. Turn the ignition switch to the On position. If the compass/temperature data is not currently being displayed, momentarily depress and release the C/T push button (5) to return to the compass/temperature display. 2. Depress and hold the RESET push button (2). Hold the push button down until "CAL" appears in the display. This takes about ten seconds. 3. Slowly drive the vehicle on a level surface, away from large metal objects and power lines, through one or two complete circles not exceeding 8 km/h (5 mph). The "CAL" message will disappear from the display to indicate that the compass is now calibrated. NOTE: A blank compass display indicates that vehicle degaussing (demagnetizing) may be necessary. NOTE: If the "CAL" message remains in the display, either there is excessive magnetism near the compass, or the CMTC is inoperative. Attempt the calibration procedure at least one more time before performing CMTC diagnosis. NOTE: If the wrong direction is still indicated in the compass display, the area selected for calibration may be too close to a strong magnetic field. Repeat the calibration procedure in another location. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Adjustments > Manual Compass Calibration > Page 14840 Trip Computer: Adjustments Compass Variance Adjustment COMPASS VARIANCE ADJUSTMENT Compass variance, also known as magnetic declination, is the difference in angle between magnetic north and true geographic north. In some geographic locations, the difference between magnetic and geographic north is great enough to cause the compass to give false readings. If this problem occurs, the compass variance must be set. NOTE: If the vehicle is taken on long trips into a new variance zone the compass function may be effected. Compass variance may need to be adjusted to the new zone number to function properly. NOTE: The default for the compass variance from the factory is 8. To set the compass variance: 1. Using the Variance Settings Map, find your geographic location and note the zone number. 2. Turn the ignition switch to the On/Run position. If the compass/temperature data is not currently being displayed, momentarily depress and release the C/T push button (5) to return to the compass/temperature display. 3. Press and hold the RESET push button (2) down for approximately five seconds. The last variance zone number will be displayed. 4. Momentarily depress and release the STEP push button (4) to toggle through the zone numbers (1-15), until the zone number for your geographic location appears in the display. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Adjustments > Manual Compass Calibration > Page 14841 5. Momentarily depress and release the RESET push button (2) to enter the displayed zone number into the compass unit memory. 6. Confirm that the correct directions are now indicated by the compass. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Service and Repair > Procedures Trip Computer: Procedures COMPASS DEMAGNETIZING A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the overhead console forward mounting screw and the roof panel above the overhead console. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 millimeters (0.25 inch) beyond the tip of the probe. To demagnetize the roof panel and the overhead console forward mounting screw, proceed as follows: 1. Be certain that the ignition switch is in the Off position, before you begin the demagnetizing procedure. 2. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 3. Slowly approach the head of the overhead console forward mounting screw with the degaussing tool connected. 4. Contact the head of the screw with the plastic coated tip of the degaussing tool for about two seconds. 5. With the degaussing tool still energized, slowly back it away from the screw. When the tip of the tool is at least 61 centimeters (2 feet) from the screw head, disconnect the tool. 6. Place a piece of paper approximately 22 by 28 centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header. The purpose of the paper is to protect the roof panel from scratches, and to define the area to be demagnetized. 7. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 8. Slowly approach the center line of the roof panel at the windshield header, with the degaussing tool connected. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Service and Repair > Procedures > Page 14844 9. Contact the roof panel with the plastic coated tip of the degaussing tool. Be sure that the template is in place to avoid scratching the roof panel. Using a slow, back-and-forth sweeping motion, and allowing 13 millimeters (0.50 inch) between passes, move the tool at least 11 centimeters (4 inches) to each side of the roof center line, and 28 centimeters (11 inches) back from the windshield header. 10. With the degaussing tool still energized, slowly back it away from the roof panel. When the tip of the tool is at least 61 centimeters (2 feet) from the roof panel, disconnect the tool. 11. Calibrate the compass and adjust the compass variance. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Service and Repair > Procedures > Page 14845 Trip Computer: Removal and Replacement Compass Mini - Trip Computer COMPASS MINI - TRIP COMPUTER 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console (3) from the headliner. 3. Remove the screws (1) that secure the Compass Mini - Trip Computer (CMTC) (4) to the overhead console housing (3). 4. Remove the CMTC (4) from the overhead console housing (3). Bulb - CMTC Control BULB - CMTC CONTROL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: There are provisions for up to three bulb/bulb holder units on the Compass Mini-Trip Computer (CMTC) circuit board. The two outboard bulbs illuminate the CMTC push buttons, while the center bulb illuminates the optional universal transmitter push buttons. Therefore, the center bulb location is only populated on vehicles equipped with the optional universal transmitter. 1. Disconnect and isolate the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Service and Repair > Procedures > Page 14846 2. Remove the overhead console (1) from the headliner. 3. Use a small thin-bladed screwdriver to rotate the bulb holder (3) counterclockwise about 30 degrees to unlock it from the keyed opening in the Compass Mini-Trip Computer (CMTC) unit (2) circuit board. 4. Pull the bulb holder and bulb straight out of the circuit board. Compass Mini - Trip Computer COMPASS MINI - TRIP COMPUTER NOTE: If a new Compass Mini - Trip Computer has been installed, the compass will have to be calibrated and the variance set. 1. Position the CMTC (4) onto the overhead console housing (3). 2. Install the screws (1) that secure the CMTC (4) to the overhead console housing (3). Tighten the screws to 2 Nm (20 in. lbs.). 3. Install the overhead console (3) onto the headliner. 4. Reconnect the battery negative cable. Bulb - CMTC Control BULB - CMTC CONTROL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: There are provisions for up to three bulb/bulb holder units on the Compass Mini-Trip Computer (CMTC) circuit board. The two outboard bulbs illuminate the CMTC push buttons, while the center bulb illuminates the optional universal transmitter push buttons. Therefore, the center bulb location is only populated on vehicles equipped with the optional universal transmitter. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Service and Repair > Procedures > Page 14847 1. Align the bulb holder and bulb (3) with the keyed opening in the circuit board of the Compass Mini-Trip Computer (CMTC) (2). 2. Insert the bulb holder and bulb straight into the circuit board until the bulb holder is firmly seated. 3. Using a small thin-bladed screwdriver, rotate the bulb holder clockwise about 30 degrees on the circuit board to lock it into place. 4. Reinstall the overhead console (1) onto the headliner. 5. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations Voice Activation Module: Locations Component ID: 206 Component : MODULE-HANDS FREE Connector: Name : MODULE-HANDS FREE Color : DK. GRAY # of pins : 22 Pin Description Circuit 1 FUSED B(+) A114 18GY/RD 2-3-4 CAN B BUS (-) D54 20WT 5 MICROPHONE 2 IN (+) X722 20LB/DG 6-7-- 8 LEFT AUDIO OUTPUT X716 20GY/TN 9 RIGHT AUDIO OUTPUT X776 20TN/GY 10 COMMON AUDIO OUTPUT X795 20DG 11 - 12 - 13 - 14 CAN B BUS (+) D55 20WT/OR 15 VOICE RECOGNITION/PHONE SWITCH SIGNAL X730 20GY/YL 16 MICROPHONE 1 IN (+) X712 20DG/LB 17 MICROPHONE IN (-) X792 20LB/DG 18 - 19 - 20 MICROPHONE FEED X793 20DG/YL 21 SENSOR GROUND X835 20OR/GY 22 GROUND Z970 18BK Component Location - 46 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations > Page 14852 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations > Page 14853 Voice Activation Module: Diagrams Component ID: 206 Component : MODULE-HANDS FREE Connector: Name : MODULE-HANDS FREE Color : DK. GRAY # of pins : 22 Pin Description Circuit 1 FUSED B(+) A114 18GY/RD 2-3-4 CAN B BUS (-) D54 20WT 5 MICROPHONE 2 IN (+) X722 20LB/DG 6-7-- 8 LEFT AUDIO OUTPUT X716 20GY/TN 9 RIGHT AUDIO OUTPUT X776 20TN/GY 10 COMMON AUDIO OUTPUT X795 20DG 11 - 12 - 13 - 14 CAN B BUS (+) D55 20WT/OR 15 VOICE RECOGNITION/PHONE SWITCH SIGNAL X730 20GY/YL 16 MICROPHONE 1 IN (+) X712 20DG/LB 17 MICROPHONE IN (-) X792 20LB/DG 18 - 19 - 20 MICROPHONE FEED X793 20DG/YL 21 SENSOR GROUND X835 20OR/GY 22 GROUND Z970 18BK Component Location - 46 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations > Page 14854 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Cable > Component Information > Service and Repair > Removal Winch Cable: Service and Repair Removal REMOVAL 1. Move the clutch lever (2) to "Free Spool" and disengage the wire rope. Pull out a portion to give it some slack. 2. Remove the clip (2), pin (1) and remove the hook (5) from the wire rope (4). 3. Pull the wire rope out and unwind the winch drum (1). 4. Remove the bolt (2) and remove the rope (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Cable > Component Information > Service and Repair > Removal > Page 14860 Winch Cable: Service and Repair Installation INSTALLATION WARNING: Always keep hands and clothing clear of the wire rope, hook and fairlead opening during operation and when spooling. Failure to follow these instructions may result in personal injury or death. CAUTION: Wire rope must spool on the winch drum in the direction indicated. 1. Feed the new wire rope end (3) through the guide rollers. 2. Attach the flat side of the wire rope end (3) to the winch drum (1), apply red thread locker to the threads and install the bolt (2). 3. Wrap the wire rope around the spool approximately one time, in the direction indicated on the spool. 4. Tighten the bolt to 3 Nm (25 in. lbs.). 5. Arrange the wire rope so it will not kink or tangle when spooled. 6. Lock the winch drum by rotating the clutch lever (2) on the winch to "Engage". NOTE: Always make sure the clutch is engaged or disengaged fully. 7. Connect the remote control to the socket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Cable > Component Information > Service and Repair > Removal > Page 14861 8. Install the hook (5), the pin (1) and clip (2) to the end of the wire rope (4). 9. Keep the rope under light tension and spool the rope back onto the winch drum in even layers. 10. Stop frequently to tighten and straighten the layers as necessary. 11. Repeat this process until the winch hook (5) is the same distance from the winch as the full length of the remote control. 12. Using the hook strap, walk the wire rope towards the guide rollers, carefully spooling in the remaining wire rope by pulsing the remote control switch. NOTE: If you do not have the hook strap, use a length of cord or similar when handling the hook during servicing of the winch. 13. Store the winch hook on the most outboard loop of the tow hook and remove the slack from the wire rope. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Motor > Component Information > Description and Operation Winch Motor: Description and Operation DESCRIPTION MOTOR The winch is driven on one end by a two direction electric motor powered by the vehicle electrical system. The motor is internally protected by a thermal switch that is activated when the motor gets too hot to operate efficiently. Winch motor controls consist of a relay pack mounted to the motor, and a remote control connected to the relay pack with a cord. The winch power source cables are connected to the relay pack which in turn feeds power to the winch motor through electrical cable connections. The main function of the relay pack is to allow the operator to switch the winch on and off in both directions. The winch relay pack also includes a Low Voltage Interrupt (LVI) used to prevent winch operation in the event of battery power dropping below 10 volts. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Motor > Component Information > Service and Repair > Removal Winch Motor: Service and Repair Removal REMOVAL 1. Remove the winch assembly (2). 2. Separate one of the roller shaft clips (1), remove the shaft (3) and the roller (4). 3. Remove the bolts (3) and separate the support bracket (1) from the winch assembly (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Motor > Component Information > Service and Repair > Removal > Page 14867 4. Remove the relay pack (1). 5. Stand winch assembly on the clutch end with the motor up to make it easier to align the motor coupler and drive shaft. 6. Remove the two motor mounting bolts (1) and carefully lift the motor (2) off of the drum assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Motor > Component Information > Service and Repair > Removal > Page 14868 Winch Motor: Service and Repair Installation INSTALLATION 1. With the winch assembly (1) standing on the clutch side verify that the motor coupler (2) is centered in the drive shaft opening (3). 2. Position the motor drive shaft into the motor coupler splines and install the motor (2). 3. Install the bolts (1) and tighten to 9 Nm (82 in. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Motor > Component Information > Service and Repair > Removal > Page 14869 4. Install the relay pack (1). 5. Install the support bracket (1) and install the bolts (3). 6. Tighten the bolts to 108 Nm (80 ft. lbs.). 7. Position the wire rope through the roller opening and install the roller (4), shaft (3) and clip (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Motor > Component Information > Service and Repair > Removal > Page 14870 8. Install the winch assembly (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Relay > Component Information > Description and Operation Winch Relay: Description and Operation DESCRIPTION RELAY PACK Electrical operation of the control assembly consists of four heavy duty relays, a thermal-switch located on the motor armature brush holder and a Low Voltage Interrupt (LVI) located in the control assembly. The thermal-switch interrupts the power-in function and the LVI affects both the power-in and power-out functions and must be reset by allowing the charging circuit voltage to rise above 10 volts for more than 30 seconds. The thermal switch is reset only by allowing the winch motor to cool adequately (about 30 minutes). Relay number 1 and 3 control current flow through the field windings and relay number 2 and 4 supply current to the motor armature. Operation In the power-out mode, relay number 2 and 3 are energized by the remote control switch. Current flows from the positive battery terminal through relay number 3 then through the black motor cable to the number 2 and number 1 field windings. From the black motor cable current then flows through solenoid number 2 to the motor armature to ground. In power-in mode, relay number 1 and 4 are energized. Current again flows from the battery positive cable, but this time current flows through solenoid number 1 then through field winding number 1. Current flowing in the reverse direction through the field windings cause the motor to turn in the opposite direction. From the red motor cable current then flows through relay number 4 to the black cable going to the motor armature to ground. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Relay > Component Information > Service and Repair > Relay Winch Relay: Service and Repair Relay Removal REMOVAL 1. Remove the relay pack (1). 2. Remove the nuts (2 & 3), disconnect the cables and remove the bus straps (4). NOTE: Relay #4 shown, all others similar. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Relay > Component Information > Service and Repair > Relay > Page 14876 3. Remove the nuts (1) and disconnect the control wires (2). 4. Slide the relay (1) out of the retaining tab (2) and remove. Installation INSTALLATION NOTE: Relay #4 shown, all others similar. 1. Slide the relay (1) into the retaining tab (2). 2. Install the control wires (2) and install the nuts (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Relay > Component Information > Service and Repair > Relay > Page 14877 3. Tighten the nuts to 3 Nm (25 in. lbs.). 4. Install the bus straps (4) and connect the cables. 5. Install the nuts (2 & 3) and tighten to 9.5 Nm (85 in. lbs.). 6. Install the relay pack (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Relay > Component Information > Service and Repair > Relay > Page 14878 Winch Relay: Service and Repair Relay Pack Removal REMOVAL 1. Disconnect and isolate battery negative cable (3). 2. Remove the winch assembly (2). 3. Remove the nut and disconnect the red battery positive cable (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Relay > Component Information > Service and Repair > Relay > Page 14879 NOTE: Relay #4 shown, all others similar. 4. Remove the control wire nuts (1) and disconnect the control wires (2) from each relay. Installation INSTALLATION NOTE: Relay #4 shown, all others similar. 1. Install the control wires (2) to all the relays and install the nuts (1). 2. Tighten the nuts to 3 Nm (25 in. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Relay > Component Information > Service and Repair > Relay > Page 14880 3. Install the red battery positive cable (1) and install the switch wire. 4. Install the nut and tighten to 10 Nm (85 in. lbs.). 5. Install the relay pack cover (1) and install the three screws (2). 6. Install the winch assembly (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Relay > Component Information > Service and Repair > Relay > Page 14881 7. Connect the battery negative cable (3) and verify winch operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Roller / Cable Guide > Component Information > Service and Repair > Removal Winch Roller / Cable Guide: Service and Repair Removal REMOVAL 1. Move the clutch lever (2) to "Free Spool" and disengage the wire rope. Pull out a portion to give it some slack. 2. Remove the clips (1). 3. Remove the roller axle rods (3) and remove the rollers (4) from the support bracket (2). 4. Separate the bushings (1) from the rollers (2) and replace if necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Roller / Cable Guide > Component Information > Service and Repair > Removal > Page 14886 5. Remove the clips (3). 6. Remove the roller axle rods (2) and remove the rollers (4) from the support bracket (1). 7. Separate the bushings (2) from the rollers (1) and replace if necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Roller / Cable Guide > Component Information > Service and Repair > Removal > Page 14887 Winch Roller / Cable Guide: Service and Repair Installation INSTALLATION 1. Install the roller bushings (2) onto the rollers (1). 2. Install the rollers (4) and install the axle rods (2). 3. Install the clips (3). 4. Install the roller bushings (1) onto the rollers (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Winch Roller / Cable Guide > Component Information > Service and Repair > Removal > Page 14888 5. Install the roller axle rods (3) and install the rollers (4) onto the support bracket (2). 6. Install the clips (1). 7. Store the winch hook on the most outboard loop of the tow hook. 8. Engage the clutch lever (2) and remove the slack from the wire rope. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14895 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14896 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14897 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14898 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14899 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14900 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14901 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14902 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14903 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14904 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14905 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14906 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14907 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14908 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14909 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14910 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14911 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14912 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Removal Front Bumper Cover / Fascia: Service and Repair Removal REMOVAL ST/SLT/SLT+ 1. Remove the two screws (4) at each trailing edge of the fascia. 2. Remove the four push pin fasteners (5) from the upper edge of the close out panel. 3. Using a trim stick (special tool #C-4755) or equivalent, carefully release the six lower clips and remove the close out panel. 4. Using a trim stick or equivalent, carefully remove the step pad (1). 5. Remove and discard the four push pin fasteners (5) and remove the fascia. SPORT 1. Raise and support the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Removal > Page 14919 2. Remove the three screws (3) at each trailing edge of the fascia. 3. Remove the five lower screws (8) . 4. Remove and discard the four upper push pins (7). 5. Using a trim stick (special tool #C-4755) or equivalent, carefully release the six lower clips and remove the close out panel. 6. Using a trim stick or equivalent, carefully remove the step pad (1). 7. Spread the fascia (2) out at the wheels and remove from the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Removal > Page 14920 Front Bumper Cover / Fascia: Service and Repair Installation INSTALLATION ST/SLT/SLT+ NOTE: The left and right inboard bumper to bracket attachments must be secured before installing the fascia and step pad. 1. Install the fascia. 2. Position the close out panel and seat the 6 lower clips fully. 3. Install four new upper push pin fasteners (5). 4. Position the step pad (1) onto the fascia (2) and fully seat the attachment clips. 5. Align the fascia to the fender with a 19 mm (0.75 inch) gap and install the two screws at each trailing edge of the fascia. SPORT NOTE: The left and right inboard bumper to bracket attachments must be secured before installing the fascia and step pad. 1. Position the fascia (2) onto the bumper. 2. Position the step pad (1) onto the fascia (2) and fully seat the attachment clips. 3. Install four new upper push pin fasteners (7). 4. Install the five lower screws (8). 5. Install the three screws (3) at each trailing edge of the fascia. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > System Information > Service and Repair > Removal Rear Bumper: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the license plate. 3. Remove the bolts behind the plate. 4. Disconnect the license plate light electrical connectors. 5. Disconnect the trailer light connector electrical connection (if equipped). 6. Remove the two bolts along the front upper edge of the bumper near the frame tips. 7. Support the bumper with a suitable lifting device. 8. Remove the bolts attaching the bumper support brackets (4) to the trailer hitch (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > System Information > Service and Repair > Removal > Page 14925 Rear Bumper: Service and Repair Installation INSTALLATION 1. Align the holes in the bumpers to the trailer hitch pins and install the bumper. 2. Loosely install the hitch bolts (2) in the support bracket (4). 3. Install the front upper edge to the trailer hitch bolts (2) and tighten to 54 Nm (40 ft. lbs.). 4. Install the license plate reinforcement to hitch bolts (2) and tighten to 54 Nm (40 ft. lbs.). 5. Tighten the left bumper bracket bolts (3) to 54 Nm (40 ft. lbs.). 6. Tighten the right bumper bracket bolts (3) to 54 Nm (40 ft. lbs.). 7. Connect the trailer light connector electrical connection (if equipped). 8. Connect the license plate light electrical connectors. 9. Install the license plate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Service and Repair > Removal Cowl: Service and Repair Removal REMOVAL 1. Remove the wiper arms. 2. Disconnect the cowl plenum washer hose from the washer supply hose at the molded plastic in-line fitting. 3. Remove the cowl weather seal from the front of the dash panel and the cowl grille (2). 4. Remove the six push pin fasteners (1) that secure the front of the cowl grille to the dash panel. 5. Remove the two screws (3) that secure the rear corners of the cowl grille to the dash panel and remove the grille. 6. If necessary, remove the washer nozzles and the cowl plenum washer hose from the cowl grille. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Service and Repair > Removal > Page 14930 Cowl: Service and Repair Installation INSTALLATION 1. If removed, install the washer nozzles and the cowl plenum washer hose onto the cowl grille (2). 2. Position the cowl grille onto the dash panel. 3. Install the two screws (3) and the six push-pin fasteners (1) that secure the cowl grille to the dash panel. 4. Install the cowl weather seal onto the front of the dash panel and the cowl grille. 5. Connect the cowl plenum washer hose to the washer supply hose at the molded plastic in-line fitting. 6. Install the wiper arms. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Front Door Exterior Handle - Installation Front Door Exterior Handle: Service and Repair Front Door Exterior Handle - Installation INSTALLATION 1. Position the exterior handle (1) into the door (4). 2. Install the two nuts (2) that secure the exterior handle to the door. Tighten the nuts to 10 Nm (89 in. lbs.). 3. Connect the actuator rods (6 and 8) for the door latch (5) to the exterior handle. 4. If equipped, connect the exterior handle wire lead (7) to the door wire harness connector (3). 5. Install the door glass. 6. Reconnect the negative battery cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Front Door Exterior Handle - Installation > Page 14939 Front Door Exterior Handle: Service and Repair Front Door Exterior Handle - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the door glass. 3. If equipped, disconnect the exterior handle wire lead (7) from the door wire harness connector (3). 4. Disconnect the actuator rods (6 and 8) for the door latch (5) from the exterior handle (1). 5. Remove the two nuts (2) that secure the exterior handle to the door (4) and remove the handle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Removal Front Door Interior Handle: Service and Repair Removal REMOVAL 1. Remove the door trim panel. 2. Position the waterdam out of the way and disconnect the actuator rod (3) from interior door handle actuator (5) and the door latch (2), if necessary. 3. Remove the two nuts (4) that secure the interior door handle actuator to the door (1) and remove the actuator. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Removal > Page 14944 Front Door Interior Handle: Service and Repair Installation INSTALLATION 1. Position the interior door handle actuator (5) onto the door (1). 2. Install the two nuts (4) that secure the interior door handle actuator to the door. Tighten the nuts to 10 Nm (89 in. lbs.). 3. Connect the actuator rod (3) to the interior door handle actuator and the door latch (2), if removed. 4. Reposition the waterdam and install the door trim panel Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Removal Front Door Hinge: Service and Repair Removal REMOVAL 1. Remove the door. 2. Using a grease pencil or equivalent, mark the hinge location and remove the bolts (3) and (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Removal > Page 14949 Front Door Hinge: Service and Repair Installation INSTALLATION NOTE: A suitable body sealant should be used when removing or moving the hinges. 1. Install the hinges and bolts. 2. Tighten the upper hinge bolt (1) to hinge pillar to 28 Nm (21 ft. lbs.). 3. Tighten the lower hinge bolt (2) to hinge pillar to 28 Nm (21 ft. lbs.). 4. Tighten the remaining hinge to hinge pillar bolts (3) and (4) to 28 Nm (21 ft. lbs.). 5. Install the door. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments Front Door Latch: Adjustments ADJUSTMENTS 1. Locate the access hole in the door to adjust the door latch (1) and remove the mylar tape (2). 2. Loosen latch adjusting screw (3) threw access slot in door shut face (1/2 to 1 full turn). 3. Operate the door handles several times to reduce any possible linkage binding and tighten the adjustment screw to 3 Nm (30 in. lbs.). 4. Operate the door handles again to verify proper operation and reinstall the mylar tape. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Removal Front Door Latch: Service and Repair Removal REMOVAL 1. Raise the window to the full up position and remove the door trim panel. 2. Position the waterdam out of the way and disconnect the actuator rod (3) from the door latch (2) and the interior door handle actuator (5) and remove the rod. 3. Disconnect the door wire harness connector (2) from the door latch (3). 4. Remove the three bolts (4) that secure the door latch to the door (1) and remove the latch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Removal > Page 14955 Front Door Latch: Service and Repair Installation INSTALLATION 1. Position the door latch (3) into the door (1). 2. Install the three bolts (4) that secure the door latch to the door. Tighten the bolts to 10 Nm (89 in. lbs.). 3. Connect the door wire harness connector (2) to the door latch. 4. Connect the actuator rod (3) to the door latch (2) and the interior door handle actuator (5). 5. Reposition the waterdam to the door (1) and install the door trim panel. 6. If necessary, adjust the latch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 23-028-07A > Jul > 07 > Audio System - Front Door Speaker Buzzing Sounds Front Door Panel: Customer Interest Audio System - Front Door Speaker Buzzing Sounds NUMBER: 23-028-07 REV. A GROUP: Body DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-028-07, DATED JULY 12, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND ADDS 2006 MODEL YEAR. SUBJECT: Buzz-Like Sound From Front Door Speaker Area When Radio Is On OVERVIEW: This bulletin involves determining the source of the buzz-like sound and making appropriate repairs. MODELS: **2006** - 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) SYMPTOM/CONDITION: The customer may a experience a buzz-like sound coming from the left and/or right front door when the radio is on. This sound in question will come from the interior door trim panel, in the area where the radio speaker is mounted. This condition may be misdiagnosed as a bad radio speaker. The actual cause may be the interface between the door trim panel sound insulation and the door water shield. DIAGNOSIS: 1. Turn the ignition switch to the "ON" position. DO NOT start the vehicle engine. 2. Turn the radio on. Set the bass and treble settings on the radio to their "centered position and fade the sound to the suspect door(s). 3. Adjust the radio volume to the # 20 position with music playing. 4. Determine if the buzz-like sound condition is present in the suspect front door(s). 5. Turn the ignition switch to the "OFF" position. 6. If the condition is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the interior trim panel on the affected door. Refer to TechCONNECT for detailed service procedures. Select the "Service Info tab > 23-Body > Door - Front> Trim Panel > Removal and Installation. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are INTEGRAL to the door trim panel. DO NOT pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 23-028-07A > Jul > 07 > Audio System - Front Door Speaker Buzzing Sounds > Page 14964 2. Remove the front door radio speaker from its mounting to the door. Do not disconnect the electrical connection to the speaker. 3. Turn the ignition switch to the "ON" position. DO NOT start the vehicle engine. 4. Hold the radio speaker by its magnet in your hand. 5. Operate the radio as described above in the Diagnosis section 6. Listen from the side of the speaker for the buzz-like sound. 7. Is the buzz-like sound coming from the speaker? a. If YES >>> then turn the ignition switch to the "OFF" position and replace the radio speaker. Proceed to the next step. b. If NO >>> then turn the ignition switch to the "OFF" position and install the radio speaker to the inner door panel. Proceed to the next step. 8. Loose fit the new sound insulation to the back side of the front door trim panel. DO NOT remove the original sound insulation from the door trim panel. The new sound insulation will install over the original door sound insulation and extends to the bottom of the door. Note the pieces of adhesive tape on the new sound insulation. 9. Remove the backing from a piece of adhesive tape and adhere the tape to the original sound insulation and/or back side of the trim panel. 10. Finish attaching the remain pieces of adhesive tape to the original sound insulation and/or back side of the trim panel. 11. Verify that the new sound insulation is installed correctly. 12. Install the interior door trim panel to the door. 13. Verify that the buzz-like sound is corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 23-028-07A > Jul > 07 > Audio System - Front Door Speaker Buzzing Sounds Front Door Panel: All Technical Service Bulletins Audio System - Front Door Speaker Buzzing Sounds NUMBER: 23-028-07 REV. A GROUP: Body DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-028-07, DATED JULY 12, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND ADDS 2006 MODEL YEAR. SUBJECT: Buzz-Like Sound From Front Door Speaker Area When Radio Is On OVERVIEW: This bulletin involves determining the source of the buzz-like sound and making appropriate repairs. MODELS: **2006** - 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) SYMPTOM/CONDITION: The customer may a experience a buzz-like sound coming from the left and/or right front door when the radio is on. This sound in question will come from the interior door trim panel, in the area where the radio speaker is mounted. This condition may be misdiagnosed as a bad radio speaker. The actual cause may be the interface between the door trim panel sound insulation and the door water shield. DIAGNOSIS: 1. Turn the ignition switch to the "ON" position. DO NOT start the vehicle engine. 2. Turn the radio on. Set the bass and treble settings on the radio to their "centered position and fade the sound to the suspect door(s). 3. Adjust the radio volume to the # 20 position with music playing. 4. Determine if the buzz-like sound condition is present in the suspect front door(s). 5. Turn the ignition switch to the "OFF" position. 6. If the condition is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the interior trim panel on the affected door. Refer to TechCONNECT for detailed service procedures. Select the "Service Info tab > 23-Body > Door - Front> Trim Panel > Removal and Installation. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are INTEGRAL to the door trim panel. DO NOT pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 23-028-07A > Jul > 07 > Audio System - Front Door Speaker Buzzing Sounds > Page 14970 2. Remove the front door radio speaker from its mounting to the door. Do not disconnect the electrical connection to the speaker. 3. Turn the ignition switch to the "ON" position. DO NOT start the vehicle engine. 4. Hold the radio speaker by its magnet in your hand. 5. Operate the radio as described above in the Diagnosis section 6. Listen from the side of the speaker for the buzz-like sound. 7. Is the buzz-like sound coming from the speaker? a. If YES >>> then turn the ignition switch to the "OFF" position and replace the radio speaker. Proceed to the next step. b. If NO >>> then turn the ignition switch to the "OFF" position and install the radio speaker to the inner door panel. Proceed to the next step. 8. Loose fit the new sound insulation to the back side of the front door trim panel. DO NOT remove the original sound insulation from the door trim panel. The new sound insulation will install over the original door sound insulation and extends to the bottom of the door. Note the pieces of adhesive tape on the new sound insulation. 9. Remove the backing from a piece of adhesive tape and adhere the tape to the original sound insulation and/or back side of the trim panel. 10. Finish attaching the remain pieces of adhesive tape to the original sound insulation and/or back side of the trim panel. 11. Verify that the new sound insulation is installed correctly. 12. Install the interior door trim panel to the door. 13. Verify that the buzz-like sound is corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 14971 Front Door Panel: By Symptom Technical Service Bulletin # 23-028-07A Date: 070720 Audio System - Front Door Speaker Buzzing Sounds NUMBER: 23-028-07 REV. A GROUP: Body DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-028-07, DATED JULY 12, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND ADDS 2006 MODEL YEAR. SUBJECT: Buzz-Like Sound From Front Door Speaker Area When Radio Is On OVERVIEW: This bulletin involves determining the source of the buzz-like sound and making appropriate repairs. MODELS: **2006** - 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) SYMPTOM/CONDITION: The customer may a experience a buzz-like sound coming from the left and/or right front door when the radio is on. This sound in question will come from the interior door trim panel, in the area where the radio speaker is mounted. This condition may be misdiagnosed as a bad radio speaker. The actual cause may be the interface between the door trim panel sound insulation and the door water shield. DIAGNOSIS: 1. Turn the ignition switch to the "ON" position. DO NOT start the vehicle engine. 2. Turn the radio on. Set the bass and treble settings on the radio to their "centered position and fade the sound to the suspect door(s). 3. Adjust the radio volume to the # 20 position with music playing. 4. Determine if the buzz-like sound condition is present in the suspect front door(s). 5. Turn the ignition switch to the "OFF" position. 6. If the condition is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the interior trim panel on the affected door. Refer to TechCONNECT for detailed service procedures. Select the "Service Info tab > 23-Body > Door - Front> Trim Panel > Removal and Installation. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are INTEGRAL to the door trim panel. DO NOT pull the door trim Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 14972 panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. 2. Remove the front door radio speaker from its mounting to the door. Do not disconnect the electrical connection to the speaker. 3. Turn the ignition switch to the "ON" position. DO NOT start the vehicle engine. 4. Hold the radio speaker by its magnet in your hand. 5. Operate the radio as described above in the Diagnosis section 6. Listen from the side of the speaker for the buzz-like sound. 7. Is the buzz-like sound coming from the speaker? a. If YES >>> then turn the ignition switch to the "OFF" position and replace the radio speaker. Proceed to the next step. b. If NO >>> then turn the ignition switch to the "OFF" position and install the radio speaker to the inner door panel. Proceed to the next step. 8. Loose fit the new sound insulation to the back side of the front door trim panel. DO NOT remove the original sound insulation from the door trim panel. The new sound insulation will install over the original door sound insulation and extends to the bottom of the door. Note the pieces of adhesive tape on the new sound insulation. 9. Remove the backing from a piece of adhesive tape and adhere the tape to the original sound insulation and/or back side of the trim panel. 10. Finish attaching the remain pieces of adhesive tape to the original sound insulation and/or back side of the trim panel. 11. Verify that the new sound insulation is installed correctly. 12. Install the interior door trim panel to the door. 13. Verify that the buzz-like sound is corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-028-07A Date: 070720 Audio System - Front Door Speaker Buzzing Sounds Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 14973 NUMBER: 23-028-07 REV. A GROUP: Body DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-028-07, DATED JULY 12, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND ADDS 2006 MODEL YEAR. SUBJECT: Buzz-Like Sound From Front Door Speaker Area When Radio Is On OVERVIEW: This bulletin involves determining the source of the buzz-like sound and making appropriate repairs. MODELS: **2006** - 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) SYMPTOM/CONDITION: The customer may a experience a buzz-like sound coming from the left and/or right front door when the radio is on. This sound in question will come from the interior door trim panel, in the area where the radio speaker is mounted. This condition may be misdiagnosed as a bad radio speaker. The actual cause may be the interface between the door trim panel sound insulation and the door water shield. DIAGNOSIS: 1. Turn the ignition switch to the "ON" position. DO NOT start the vehicle engine. 2. Turn the radio on. Set the bass and treble settings on the radio to their "centered position and fade the sound to the suspect door(s). 3. Adjust the radio volume to the # 20 position with music playing. 4. Determine if the buzz-like sound condition is present in the suspect front door(s). 5. Turn the ignition switch to the "OFF" position. 6. If the condition is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the interior trim panel on the affected door. Refer to TechCONNECT for detailed service procedures. Select the "Service Info tab > 23-Body > Door - Front> Trim Panel > Removal and Installation. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are INTEGRAL to the door trim panel. DO NOT pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. 2. Remove the front door radio speaker from its mounting to the door. Do not disconnect the electrical connection to the speaker. 3. Turn the ignition switch to the "ON" position. DO NOT start the vehicle engine. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 14974 4. Hold the radio speaker by its magnet in your hand. 5. Operate the radio as described above in the Diagnosis section 6. Listen from the side of the speaker for the buzz-like sound. 7. Is the buzz-like sound coming from the speaker? a. If YES >>> then turn the ignition switch to the "OFF" position and replace the radio speaker. Proceed to the next step. b. If NO >>> then turn the ignition switch to the "OFF" position and install the radio speaker to the inner door panel. Proceed to the next step. 8. Loose fit the new sound insulation to the back side of the front door trim panel. DO NOT remove the original sound insulation from the door trim panel. The new sound insulation will install over the original door sound insulation and extends to the bottom of the door. Note the pieces of adhesive tape on the new sound insulation. 9. Remove the backing from a piece of adhesive tape and adhere the tape to the original sound insulation and/or back side of the trim panel. 10. Finish attaching the remain pieces of adhesive tape to the original sound insulation and/or back side of the trim panel. 11. Verify that the new sound insulation is installed correctly. 12. Install the interior door trim panel to the door. 13. Verify that the buzz-like sound is corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel Front Door Panel: Service and Repair Front Door Trim Panel Removal REMOVAL 1. Remove the screw (1) that secures the interior door handle (2) to the interior door handle actuator (3). 2. Remove the interior door handle from the interior door handle actuator. 3. If equipped, remove the manual window crank (1) using a window crank removal tool (2). 4. Remove the two screws (2) that secure the door trim panel (3) to the two screw inserts (1). 5. Remove the two screws (4) that secure the door trim panel to the bottom of the door. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not pull Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel > Page 14977 the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. 6. Lift the door trim panel straight upward to disconnect the molded plastic retaining clips (5) from the door. 7. If equipped, disconnect the door wire harness from the power door switch assembly and remove the door trim panel. Installation INSTALLATION 1. If equipped, connect the door wire harness to the power door switch assembly. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not force the door trim panel onto the door or damage to the trim panel and/or the power switch assembly will occur. 2. Position the door trim panel (3) and align the molded plastic retaining clips (5) to the door. 3. Push the door trim panel straight downward until all of the retaining clips are fully engaged to the door. 4. Install the two screws (2) that secure the door trim panel to the two screw inserts (1). 5. Install the two screws (4) that secure the door trim panel to the bottom of the door. 6. If equipped, install the manual window crank. 7. Position the interior door handle (2) onto the interior door handle actuator (3). 8. Install the screw (1) that secures the interior door handle to the interior door handle actuator. Tighten the screw securely. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel > Page 14978 Front Door Panel: Service and Repair Waterdam Removal REMOVAL 1. Remove the interior door handle actuator. 2. Remove the speaker. CAUTION: Do not allow the waterdam adhesive to become contaminated with dirt or other foreign substances. If the waterdam becomes contaminated or damaged, replace it. 3. Carefully remove the waterdam (1) from around the perimeter of the door (2). 4. Separate the waterdam from the interior handle actuator rod and the door wire harness (if equipped) and remove the waterdam. Installation INSTALLATION CAUTION: Do not allow the waterdam or adhesive to become contaminated with dirt or other foreign substances. If the waterdam becomes contaminated or damaged, replace it. NOTE: Be sure that the waterdam is fully sealed around the perimeter of the door. 1. Position the interior handle actuator rod and the wire harness (if equipped) through the holes in the waterdam (1) and install the waterdam to the door (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel > Page 14979 2. Install the speaker. 3. Install the interior door handle actuator. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel > Page 14980 Front Door Panel: Service and Repair Side View Mirror Flag Removal REMOVAL 1. Remove the door trim panel (4). CAUTION: Do not use a drill to remove the heat stakes. The remaining portions of the heat stake studs are needed for installation purposes. Failure to follow this caution may require door trim panel replacement. 2. Remove the heat stakes (3) using a razor knife or equivalent. 3. Release the tabs (2) and remove the mirror flag (1) from the door trim panel. Installation INSTALLATION NOTE: Clean any excess heat stake material off of the heat stake studs to aid in mirror flag installation. 1. Install the mirror flag (1) over the tabs (2) and install the screws (3) into the heat stake studs. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel > Page 14981 2. Install the door trim panel (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments Front Door Striker: Adjustments ADJUSTMENTS 1. Using a grease pencil or equivalent, mark the location of the door latch striker (1) on the B-pillar (2) to aid in adjustment. 2. Loosen the two bolts (3) that secure the door latch striker to the B-pillar. 3. To adjust the rear gap and flush measurement, change the position of the door latch striker and then tighten the two bolts to 28 Nm (21 ft. lbs.). 4. Verify correct door and latch position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Removal Front Door Striker: Service and Repair Removal REMOVAL 1. Using a grease pencil or equivalent, mark the location of the door latch striker (1) on the B-pillar (2). 2. Remove the two bolts (3) that secure the door latch striker to the B-pillar and remove the striker. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Removal > Page 14987 Front Door Striker: Service and Repair Installation INSTALLATION 1. Position the door latch striker (1) onto the B-pillar (2) and loosely install the two bolts (3). 2. Align the door latch striker to the B-pillar using the reference marks made during the removal procedure and tighten the bolts to 28 Nm (21 ft. lbs.). 3. If necessary, adjust the door latch striker. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip Front Door Weatherstrip: Service and Repair Drip Rail Weatherstrip Removal REMOVAL 1. Open the doors and separate the weatherstrip (3) from the drip rail and a-pillar retainers (1 and 7). Installation INSTALLATION 1. Position the weatherstrip (3) onto the drip rail and a-pillar retainers (1 and 7) and seat fully. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 14992 Front Door Weatherstrip: Service and Repair A-Pillar Weatherstrip Retainer Removal REMOVAL 1. Remove the drip rail weatherstrip retainer (1) 2. Remove the five screws (8) and remove the A-pillar weatherstrip retainer (7). Installation INSTALLATION 1. Install the A-pillar weatherstrip retainer (7) and install the screws (8). 2. Install the drip rail weatherstrip retainer (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 14993 Front Door Weatherstrip: Service and Repair Door Opening Seal Removal REMOVAL FRONT DOOR SEAL 1. Remove the cowl trim panel (1). 2. If vehicle is a Standard Cab, remove the lower b-pillar trim panel (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 14994 3. If vehicle is a Quad Cab, remove the lower b-pillar trim panel (1). 4. Separate the front door opening seal (6) from the door opening flange. REAR DOOR SEAL 1. Remove the lower b-pillar trim panel (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 14995 2. Remove the lower c-pillar trim (1). 3. Separate the rear door opening seal (5) from the door opening flange. Installation INSTALLATION FRONT DOOR SEAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 14996 1. Position the front door seal (6) to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. If vehicle is a Standard Cab, install the lower b-pillar trim (3). 3. If vehicle is a Quad Cab, install the lower b-pillar trim (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 14997 4. Install the cowl trim panel (1). NOTE: When installing a new weatherstrip on the front door opening, remove the tear strip starting at the splice and moving around the front of the door to the back of the opening. REAR DOOR SEAL 1. Position the rear door seal to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 14998 2. Install the lower c-pillar trim (1). 3. Install the lower b-pillar trim (1). NOTE: When installing a new weatherstrip on the rear door opening, remove the tear strip starting at the splice and moving around the back of the door to the front of the opening. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 14999 Front Door Weatherstrip: Service and Repair Drip Rail Weatherstrip Retainer Removal REMOVAL 1. Separate the drip rail weatherstrip (3) from the weatherstrip retainer (1). 2. Remove the seven screws (2) and remove the retainer (1). Installation INSTALLATION 1. Install the weatherstrip retainer (1) and install the seven screws (2). 2. Position the weatherstrip (3) over the retainer flange and seat fully. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding Front Door Window Glass Weatherstrip: Service and Repair Front Door Outer Belt Molding Removal REMOVAL 1. Remove the screw (4) and separate the belt molding (1) from the door (5) flange from the back to the front. Installation INSTALLATION 1. Position the belt molding (1) onto the door (5) flange and seat fully. 2. Install the screw (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 15005 Front Door Window Glass Weatherstrip: Service and Repair Front Door Glass Run Weatherstrip Removal REMOVAL 1. Remove the door glass. 2. Separate the front door glass run weatherstrip (2) out of the door frame (5) and remove through the window opening. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 15006 NOTE: A mixture of soap and water may be used to aid installation of the weatherstrip into the corners. 1. Position the front door glass run weatherstrip (2) into the door (5) through the window opening. 2. Position the weatherstrip into the upper corners and seat firmly. 3. From back to front, seat the weatherstrip between the corners and then down the sides firmly. 4. Install the door glass. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 15007 Front Door Window Glass Weatherstrip: Service and Repair Front Door Inner Belt Molding Removal REMOVAL 1. Remove the door trim panel (3). 2. Separate the belt molding (1) from the door (3) mounting flange from the back to the front. Installation INSTALLATION 1. Position the belt molding (1) and seat onto the door (3) mounting flange fully. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 15008 2. Install the door trim panel (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Power Front Door Window Regulator: Service and Repair Front Door Window Regulator - Power Removal REMOVAL 1. Remove the inner belt molding. 2. Remove the waterdam. 3. Remove the electric window switch from the door trim panel and connect it to the door wire harness. 4. Raise the door glass to the position shown. 5. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 6. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 7. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 8. Remove the bolt (5) that secures the window regulator to the door and loosen the other two regulator bolts (7). 9. Slide the window regulator upward and disengage the two regulator bolts from the door. 10. Remove the window regulator through the opening in the door and disconnect the door wire harness (6). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Power > Page 15013 Installation INSTALLATION 1. Connect the door wire harness (6) to the window regulator (4) and install the regulator through the opening in the door (2). 2. Engage the two regulator bolts (7) to the door. 3. Install the bolt (5) that secure the window regulator to the door and tighten all three regulator bolts to 10 Nm (89 in. lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 Nm (89 in. lbs.). 5. Raise the window regulator (2) to the position shown. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 Nm (89 in. lbs.). 8. Disconnect the electric window switch from the door wire harness and reinstall the switch onto the door trim panel. 9. Install the waterdam. 10. Install the inner belt molding. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Power > Page 15014 Front Door Window Regulator: Service and Repair Front Door Window Regulator - Manual Removal REMOVAL 1. Remove the inner belt molding. 2. Remove the waterdam. 3. Reinstall the manual window crank and raise the door glass to the position shown. 4. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 5. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 6. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 7. Remove the two bolts (5) that secure the window regulator to the door and loosen the other two regulator bolts (6). 8. Slide the window regulator upward and disengage the two regulator bolts from the door. 9. Remove the window regulator through the opening in the door. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Power > Page 15015 1. Install the window regulator (4) through the opening in the door (2). 2. Engage the two regulator bolts (6) to the door. 3. Install the two bolt (5) that secure the window regulator to the door and tighten all four regulator bolts to 10 Nm (89 in. lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 Nm (89 in. lbs.). 5. Raise the window regulator (2) to the position shown and remove the manual window crank. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 Nm (89 in. lbs.). 8. Install the waterdam. 9. Install the inner belt molding. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Rear Door Exterior Handle - Removal Rear Door Exterior Handle: Service and Repair Rear Door Exterior Handle - Removal REMOVAL 1. Remove the front glass run channel. 2. Disconnect the actuator rod (1) from the exterior door handle (2). 3. Remove the two nuts (3) that secure the exterior door handle to the door and remove the handle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Rear Door Exterior Handle - Removal > Page 15022 Rear Door Exterior Handle: Service and Repair Rear Door Exterior Handle - Installation INSTALLATION 1. Position the exterior handle (2) into the door. 2. Install the two nuts (3) that secure the exterior handle to the door. Tighten the nuts to 10 Nm (89 in. lbs.). 3. Connect the actuator rod (1) to the exterior handle. 4. Install the front glass run channel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair > Removal Rear Door Interior Handle: Service and Repair Removal REMOVAL 1. Remove the door trim panel. 2. Position the waterdam out of the way and disconnect the actuator rod (2) from interior door handle actuator (3). 3. Remove the two bolts (1) that secure the interior door handle actuator to the door and remove the actuator. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair > Removal > Page 15027 Rear Door Interior Handle: Service and Repair Installation INSTALLATION 1. Position the interior door handle actuator (3) onto the door. 2. Install the two bolts (1) that secure the interior door handle actuator to the door. Tighten the bolts to 10 Nm (89 in. lbs.). 3. Connect the actuator rod (2) to the interior door handle actuator. 4. Reposition the waterdam and install the door trim panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Removal Rear Door Hinge: Service and Repair Removal REMOVAL NOTE: It is not necessary to remove the door to replace the hinges if they are replaced one at a time. NOTE: The epoxy coated washers should not be removed from the hinge. If the washers are removed the door may have to be re-adjusted. 1. Open the front door UPPER HINGE 1. Using a grease pencil or equivalent, mark the position of the hinge (2) on the door and b-pillar. 2. Remove the nut (1) and bolt (9) attaching the hinge (2) to the door. 3. Remove the three bolts (6) attaching the hinge to the b-pillar and remove the hinge. LOWER HINGE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Removal > Page 15032 1. Using a grease pencil or equivalent, mark the position of the hinge on the door and b-pillar. 2. Remove the lower b-pillar trim. 3. Remove the nut (1) and bolt (9) attaching the hinge to the door. 4. Remove the two bolts (5) attaching the hinge to the b-pillar. 5. From the inside of the vehicle remove the remaining bolt (4) attaching the hinge to the b-pillar and remove the hinge. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Removal > Page 15033 Rear Door Hinge: Service and Repair Installation INSTALLATION UPPER HINGE 1. Install the hinge to door washers, if there were removed previously, nut (1) and bolt (9) and tighten to 28 Nm (21 ft. lbs.). 2. Tighten the upper hinge bolt (2) to 28 Nm (21 ft. lbs.). 3. Tighten the upper hinge bolt (1) to 28 Nm (21 ft. lbs.). 4. Tighten the upper hinge bolt (3) to 28 Nm (21 ft. lbs.). 5. Adjust the door if needed. LOWER HINGE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Removal > Page 15034 1. Install the hinge and install the b-pillar bolts. 2. Tighten the upper hinge bolt (2) to 28 Nm (21 ft. lbs.). 3. Tighten the upper hinge bolt (1) to 28 Nm (21 ft. lbs.). 4. Tighten the upper hinge bolt (3) to 28 Nm (21 ft. lbs.). 5. Install the hinge to door washers, if there were removed previously, nut and bolt and tighten to 28 Nm (21 ft. lbs.). 6. Adjust the door if needed. 7. Install the lower b-pillar trim. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Adjustments Rear Door Latch: Adjustments ADJUSTMENTS 1. Locate the access hole in the door to adjust the door latch (1) and remove the mylar tape (2). 2. Loosen the adjustment screw (3). 3. Operate the door handles several times to reduce any possible linkage binding and tighten the adjustment screw to 3 Nm (30 in. lbs.). 4. Operate the door handles again to verify proper operation and reinstall the mylar tape. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Removal Rear Door Latch: Service and Repair Removal REMOVAL 1. Raise the window to the full up position and remove the door trim panel. 2. Position the waterdam out of the way and disconnect the actuator rod (1) from the interior door handle actuator (2) and the door latch (5) and remove the rod. 3. Disconnect the two actuator rods (3 and 4) from the door latch. 4. Disconnect the door wire harness connector (2) from the door latch (3). 5. Remove the three bolts (4) that secure the door latch to the door (1) and remove the latch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Removal > Page 15040 Rear Door Latch: Service and Repair Installation INSTALLATION 1. Position the door latch (3) into the door (1). 2. Install the three bolts (4) that secure the door latch to the door. Tighten the bolts to 10 Nm (89 in. lbs.). 3. Connect the door wire harness connector (2) to the door latch. 4. Connect the two actuator rods (3 and 4) to the door latch (5) 5. Connect the actuator rod (1) to the door latch and the interior door handle actuator (2). 6. Reposition the waterdam to the door and install the door trim panel. 7. If necessary, adjust the latch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Trim Panel Rear Door Panel: Service and Repair Trim Panel Removal REMOVAL 1. Remove the screw (3) that secures the interior door handle (2) to the interior door handle actuator (1). 2. Remove the interior door handle from the interior door handle actuator. 3. If equipped, remove the manual window crank (2) using a window crank removal tool (1). 4. Remove the screw (4) that secures the door trim panel (5) to the screw insert located in the center of the door (1). CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not pull Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Trim Panel > Page 15045 the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. 5. Lift the door trim panel straight upward to disconnect the molded plastic retaining clips (3) from the door. 6. If equipped, disconnect the door wire harness (2) from the power door switch assembly and remove the door trim panel. Mega Cab 1. Remove the screws (3) that secures the door trim panel to the door. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips (4) that are integral to the door trim panel. Do not pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. 2. Lift the door trim panel straight upward to disconnect the molded plastic retaining clips (4) from the door. 3. If equipped, disconnect the door wire harness (2) from the power door switch assembly and remove the door trim panel. Installation INSTALLATION 1. If equipped, connect the door wire harness (2) to the power door switch assembly. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not force the door trim panel onto the door or damage to the trim panel and/or the power switch assembly will occur. 2. Position the door trim panel (5) and align the molded plastic retaining clips (3) to the door (1). 3. Push the door trim panel straight downward until all of the retaining clips are fully engaged to the door. 4. Install the screw (4) that secures the door trim panel to the screw insert located in the center of the door. 5. if equipped, install the manual window crank. Mega Cab Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Trim Panel > Page 15046 1. If equipped, connect the door wire harness (2) to the power door switch assembly. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips (4) that are integral to the door trim panel. Do not force the door trim panel onto the door or damage to the trim panel and/or the power switch assembly will occur. 2. Position the trim panel to the door and insert the door lock (1) through the hole in the trim panel. 3. Position the door trim panel and align the molded plastic retaining clips (4) to the door slots (5). 4. Push the door trim panel straight downward until all of the retaining clips are fully engaged to the door. 5. Install the screws (3). 6. if equipped, install the manual window crank. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Trim Panel > Page 15047 Rear Door Panel: Service and Repair Waterdam Removal REMOVAL 1. Remove the interior door handle actuator. 2. Remove the speaker. CAUTION: Do not allow the waterdam adhesive to become contaminated with dirt or other foreign substances. If the waterdam becomes contaminated or damaged, replace it. 3. Carefully remove the waterdam (1) from around the perimeter of the rear door (2). 4. Separate the waterdam from the interior handle actuator rod and the door wire harness (if equipped) and remove the waterdam. Installation INSTALLATION CAUTION: Do not allow the waterdam or adhesive to become contaminated with dirt or other foreign substances. If the waterdam becomes contaminated or damaged, replace it. NOTE: Be sure that the waterdam is fully sealed around the perimeter of the door. 1. Position the interior handle actuator rod and the wire harness (if equipped) through the holes in the waterdam (1) and install the waterdam to the door (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Trim Panel > Page 15048 2. Install the speaker. 3. Install the interior door handle actuator. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Adjustments Rear Door Striker: Adjustments ADJUSTMENTS 1. Using a grease pencil or equivalent, mark the location of the door latch striker (1) on the C-pillar (2) to aid in adjustment. 2. Loosen the two bolts (3) that secure the door latch striker to the C-pillar. 3. To adjust the rear gap and flush measurement, change the position of the door latch striker and then tighten the two bolts to 28 Nm (21 ft. lbs.). 4. Verify correct door and latch position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Service and Repair > Removal Rear Door Striker: Service and Repair Removal REMOVAL 1. Using a grease pencil or equivalent, mark the location of the door latch striker (1) on the C-pillar (2). 2. Remove the two bolts (3) that secure the door latch striker to the C-pillar and remove the striker. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Service and Repair > Removal > Page 15054 Rear Door Striker: Service and Repair Installation INSTALLATION 1. Position the door latch striker (1) onto the C-pillar (2) and loosely install the two bolts (3). 2. Align the door latch striker to the C-pillar using the reference marks made during the removal procedure and tighten the bolts to 28 Nm (21 ft. lbs.). 3. If necessary, adjust the door latch striker. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip Rear Door Weatherstrip: Service and Repair Drip Rail Weatherstrip Removal REMOVAL 1. Open the doors and separate the weatherstrip (3) from the drip rail and a-pillar retainers (1 and 7). Installation INSTALLATION 1. Position the weatherstrip (3) onto the drip rail and a-pillar retainers (1 and 7) and seat fully. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 15059 Rear Door Weatherstrip: Service and Repair A-Pillar Weatherstrip Retainer Removal REMOVAL 1. Remove the drip rail weatherstrip retainer (1) 2. Remove the five screws (8) and remove the A-pillar weatherstrip retainer (7). Installation INSTALLATION 1. Install the A-pillar weatherstrip retainer (7) and install the screws (8). 2. Install the drip rail weatherstrip retainer (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 15060 Rear Door Weatherstrip: Service and Repair Drip Rail Weatherstrip Retainer Removal REMOVAL 1. Separate the drip rail weatherstrip (3) from the weatherstrip retainer (1). 2. Remove the seven screws (2) and remove the retainer (1). Installation INSTALLATION 1. Install the weatherstrip retainer (1) and install the seven screws (2). 2. Position the weatherstrip (3) over the retainer flange and seat fully. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 15061 Rear Door Weatherstrip: Service and Repair Door Opening Seal Removal REMOVAL FRONT DOOR SEAL 1. Remove the cowl trim panel (1). 2. If vehicle is a Standard Cab, remove the lower b-pillar trim panel (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 15062 3. If vehicle is a Quad Cab, remove the lower b-pillar trim panel (1). 4. Separate the front door opening seal (6) from the door opening flange. REAR DOOR SEAL 1. Remove the lower b-pillar trim panel (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 15063 2. Remove the lower c-pillar trim (1). 3. Separate the rear door opening seal (5) from the door opening flange. Installation INSTALLATION FRONT DOOR SEAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 15064 1. Position the front door seal (6) to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. If vehicle is a Standard Cab, install the lower b-pillar trim (3). 3. If vehicle is a Quad Cab, install the lower b-pillar trim (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 15065 4. Install the cowl trim panel (1). NOTE: When installing a new weatherstrip on the front door opening, remove the tear strip starting at the splice and moving around the front of the door to the back of the opening. REAR DOOR SEAL 1. Position the rear door seal to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 15066 2. Install the lower c-pillar trim (1). 3. Install the lower b-pillar trim (1). NOTE: When installing a new weatherstrip on the rear door opening, remove the tear strip starting at the splice and moving around the back of the door to the front of the opening. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Outer Belt Molding Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Outer Belt Molding Removal REMOVAL 1. Remove the screw (3) and separate the belt molding (1) from the door (2) flange from the back to the front. Installation INSTALLATION 1. Position the belt molding (1) onto the door (2) flange and seat fully. 2. Install the screw (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Outer Belt Molding > Page 15072 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Run Weatherstrip Removal REMOVAL 1. Lower the glass. 2. Separate the rear door glass run weatherstrip (5) out of the door frame (2) and remove through the window opening. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Outer Belt Molding > Page 15073 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Outer Belt Molding > Page 15074 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Inner Belt Molding Removal REMOVAL 1. Remove the door trim panel (5). 2. Separate the belt molding (2) from the rear door mounting flange from the back to the front. Installation INSTALLATION 1. Position the belt molding (2) and seat onto the rear door mounting flange fully. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Outer Belt Molding > Page 15075 2. Install the door trim panel (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Window Regulator - Power Rear Door Window Regulator: Service and Repair Window Regulator - Power Removal REMOVAL 1. Remove the inner belt molding. 2. Remove the waterdam. 3. Remove the electric window switch from the door trim panel and connect it to the door wire harness. 4. Raise the door glass to the position shown. 5. Remove the two nuts (1) that secure the door glass (2) to the window regulator (3) through the speaker opening (5) and the sight window (4) and disengage the door glass from the regulator. 6. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 7. Lower the window regulator and remove the two nuts (1) that secure the regulator stabilizer to the door. 8. Remove the bolts (2) that secures the window regulator to the door and loosen the other two regulator bolts (3). 9. Slide the window regulator upward and disengage the two regulator bolts from the door. 10. Remove the window regulator through the opening in the door and disconnect the door wire harness (4). Installation Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Window Regulator - Power > Page 15080 INSTALLATION 1. Connect the door wire harness (4) to the window regulator and install the regulator through the opening in the door. 2. Engage the two regulator bolts (3) to the door. 3. Install the regulator bolts (2) that secures the window regulator to the door and tighten all regulator bolts to 10 Nm (89 in. lbs.). 4. Position the regulator stabilizer into the door and install the two nuts. Tighten the nuts to 10 Nm (89 in. lbs.). 5. Raise the window regulator (3) to the position shown. 6. Support the door glass (2) and remove the wooden wedge or equivalent. 7. Position the door glass to the window regulator and install the two nuts (1) that secure the door glass to the window regulator (3) through the sight window (4) and the speaker opening (5). Tighten the nuts to 10 Nm (89 in. lbs.). 8. Disconnect the electric window switch from the door wire harness and reinstall the switch onto the door trim panel. 9. Install the waterdam. 10. Install the inner belt molding. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Window Regulator - Power > Page 15081 Rear Door Window Regulator: Service and Repair Window Regulator - Manual Removal REMOVAL 1. Remove the inner belt molding. 2. Remove the waterdam. 3. Reinstall the manual window crank and raise the door glass to the position shown. 4. Remove the two nuts (1) that secure the door glass (2) to the window regulator (3) through the speaker opening (5) and the sight window (4) and disengage the door glass from the regulator. 5. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 6. Lower the window regulator (5) and remove the two nuts (3) that secure the regulator stabilizer (4) to the door (1). 7. Remove the two bolts (2) that secure the window regulator to the door and loosen the other two regulator bolts (6). 8. Slide the window regulator upward and disengage the two regulator bolts from the door. 9. Remove the window regulator through the opening in the door. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Window Regulator - Power > Page 15082 1. Install the window regulator (5) through the opening in the door (1). 2. Engage the two regulator bolts (6) to the door. 3. Install the two bolts (2) that secure the window regulator to the door and tighten all four regulator bolts to 10 Nm (89 in. lbs.). 4. Position the regulator stabilizer (4) onto the door and install the two nuts (3). Tighten the nuts to 10 Nm (89 in. lbs.). 5. Raise the window regulator (3) to the position shown and remove the manual window crank. 6. Support the door glass (2) and remove the wooden wedge or equivalent. 7. Position the door glass to the window regulator and install the two nuts (1) that secure the door glass to the window regulator through the sight window (4) and the speaker opening (5). Tighten the nuts to 10 Nm (89 in. lbs.). 8. Install the waterdam. 9. Install the inner belt molding. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Removal Fuel Door: Service and Repair Removal REMOVAL 1. Open the fuel filler door (1). 2. Remove the two bolts (2) that secure the fuel filler door to the cargo box and remove the door. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Removal > Page 15087 Fuel Door: Service and Repair Installation INSTALLATION 1. Position and align the fuel filler door (1) to the cargo box. 2. Install the two bolts (2) that secure the fuel filler door to the cargo box. Tighten the bolts to 9 Nm (80 in. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Removal Hood Hinge: Service and Repair Removal REMOVAL NOTE: It is not necessary to remove the hood to replace the hood hinges. Hood hinges can be replaced one at a time. 1. Remove the cowl grille. 2. Using a grease pencil or equivalent, mark the position of the hood hinge (3) on the hood for the hinge being serviced. 3. Support the hood and disconnect the support cylinder from the hood. 4. Remove the two nuts that secure the hood to the hood hinge. 5. Remove the bolt (2) that secures the front fender (1) to the hood hinge. 6. Remove the wheelhouse splash shield. 7. Remove the bolts (3) that secure the hood hinge (2) to the fender rail (1). 8. Slide the hood hinge forward and remove the hinge. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Removal > Page 15093 Hood Hinge: Service and Repair Installation INSTALLATION NOTE: It is not necessary to remove the hood to replace the hood hinges. Hood hinges can be replaced one at a time. 1. Position the hood hinge (2) onto the fender rail (1) and slide it rearward to its installed location. 2. Install the bolts (3) that secure the hood hinge to the fender rail. Tighten the bolts to 20 Nm (15 ft. lbs.). 3. Install the bolt (2) that secures the front fender (1) to the hood hinge (3). Tighten the bolt to 12.5 Nm (9 ft. lbs.). 4. Loosely install the two nuts that secure the hood to the hood hinge. 5. Align the hood to the hood hinge using the reference marks made during the Removal procedure and tighten the nuts to 23 Nm (17 ft. lbs.). 6. Install the support cylinder. 7. If required, adjust the hood to the correct position. 8. Install the wheelhouse splash shield. 9. Install the cowl grille. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Latch Hood Latch: Service and Repair Latch Removal REMOVAL 1. Using a grease pencil or equivalent, mark the position of the hood latch (1) on the upper radiator crossmember. 2. Remove the two bolts (3) that secure the hood latch to the upper radiator crossmember. 3. Disconnect the hood latch cable (2) from the hood latch and remove the latch. Installation INSTALLATION 1. Connect the hood latch cable (2) to the hood latch (1). 2. Position the hood latch to the upper radiator crossmember and loosely install the two bolts (3) that secure the latch to the crossmember. 3. Align the hood latch to the upper radiator crossmember using the reference marks made during the Removal procedure and tighten the bolts to 11 Nm (8 ft. lbs.). 4. If required, adjust the hood to the correct position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Latch > Page 15098 Hood Latch: Service and Repair Latch Striker / Secondary Catch Removal REMOVAL 1. Disconnect the release handle (4) from the secondary hood latch and striker assembly (2) and remove the handle from the grille frame (5). 2. Remove the two bolts (3) that secure the secondary hood latch and striker assembly to the hood and remove the assembly. Installation INSTALLATION 1. Position the secondary hood latch and striker assembly (2) to the hood. 2. Install the two bolts (3) that secure the secondary hood latch and striker assembly to the hood. Tighten the bolts to 11 Nm (8 ft. lbs.). 3. Install the release handle (4) through the grille frame (5) and connect it to the secondary hood latch. 4. If required, adjust the hood to the correct position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Removal Hood Latch Release Cable: Service and Repair Removal REMOVAL 1. Remove the hood latch. 2. Remove the battery tray from the left side of the engine compartment. 3. Remove the three hood release cable retainers from the upper radiator crossmember and the left fender rail. 4. From inside the vehicle, remove the two bolts (1) that secure the hood release handle (2) to the instrument panel bracket (3). 5. Remove the grommet (4) from the cowl panel and remove the hood release cable and handle assembly. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Removal > Page 15103 Hood Latch Release Cable: Service and Repair Installation INSTALLATION 1. Route the hood release cable through the cowl panel and install the grommet (4). 2. Position the hood release handle (2) onto the instrument panel bracket (3). 3. Install the two bolts (1) that secure the hood release handle to the instrument panel bracket. Tighten the bolts to 9 Nm (80 in. lbs.). 4. Route the hood release cable along the left fender rail and the upper radiator crossmember and install the three hood release cable retainers. 5. Install the battery tray to the left side of the engine compartment. 6. Install the hood latch . Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Service and Repair > Removal Hood Shock / Support: Service and Repair Removal REMOVAL NOTE: The hood support cylinders can be replaced one at a time. 1. Open and support the hood. CAUTION: Do not pull on the hood support cylinders at the middle of the support cylinder during removal. Failure to follow this caution can result in damage to the hood support cylinders. 2. Using a small flat bladed tool, or equivalent (3), release the retaining clip (2) at each end of the support cylinder while carefully pulling the ball socket (1) away from the ball stud (4). NOTE: Lift the clips (1) only enough to release the ball studs (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Service and Repair > Removal > Page 15108 3. Disconnect the hood support cylinder (5) from the hood (1) and the fender rail (3). 4. If required, remove the upper ball stud (2) from hood and the lower ball stud (4) from the fender rail. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Service and Repair > Removal > Page 15109 Hood Shock / Support: Service and Repair Installation INSTALLATION 1. If removed, install the upper ball stud (2) onto the hood (1) and the lower ball stud (4) onto the fender rail (3). Install the ball studs securely. CAUTION: Do not push on the hood support cylinders at the middle of the support cylinder during installation. Failure to follow this caution can result in damage to the hood support cylinders. NOTE: Install the hood support cylinders with the cylinder end connected to the hood as shown. NOTE: If required, only release each retaining clip enough to install the ball socket onto the ball stud. 2. Install the hood support cylinder (5) over the upper and lower ball studs and fully engage the retaining clips. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Customer Interest for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood Hood Sensor/Switch (For Alarm): Customer Interest Antitheft System - Goes Off When Opening The Hood NUMBER: 08-040-06 GROUP: Electrical DATE: September 06, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: Vehicle Theft Security System Alarm May Alert When Hood Is Opened OVERVIEW: This bulletin involves selectively erasing and reprogramming the Cabin Compartment Node Module (CCN) with new software. MODELS: 2007 (DR/DH/D1/DC) Ram Truck NOTE: This bulletin applies to vehicles equipped with a remote start system (sales code XBM) prior to October 10, 2006 (MDH 1010XX). SYMPTOM/CONDITION: The Vehicle Theft Security System (VTSS) may alert (flash lights and/or sound horn) if one of the following occurs: a. The customer arms the VTSS and then reaches through an open window, pulls on the hood release, and fully opens the vehicle hood. b. The customer releases the hood but not enough to open the hood ajar switch, arms the VTSS, and then fully opens the vehicle hood. c. The customer opens the hood, arms the VTSS, the vehicle communications bus goes in to "sleep mode" (may take 10 minutes), then the "LOCK" button on the key fob is depressed. The hood ajar switch is not part of the VTSS used on domestic use vehicles. The hood ajar switch is used for export vehicles equipped with the Vehicle Theft Alarm (VTA) system. DIAGNOSIS: 1. Connect the StarSCAN(R) to the vehicle. 2. Power up the StarSCAN(R) and obtain the HOME menu. 3. From the HOME menu select "ECU VIEW". 4. Select "CCN - Cabin Compartment". 5. Select "More Options". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Customer Interest for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 15119 6. Select "ECU Flash" 7. Read and record the software part number that is display with "Resident Flash File For Part". 8. Is the software part number 05172187AC (or later)? a. If YES >>> then STOP. This bulletin does not apply. Further diagnosis is required. b. If NO >>> then perform the Repair Procedure. NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the CCN in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash CCN" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Customer Interest for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 15120 13. Highlight the listed calibration. 14. Select "Update Controller". Follow on screen instructions. 15. When the CCN update is complete, select "OK". 16. Verify the part number at the top of the "Flash CCN" screen has updated to the new part number. NOTE: Due to the CCN programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood Hood Sensor/Switch (For Alarm): All Technical Service Bulletins Antitheft System - Goes Off When Opening The Hood NUMBER: 08-040-06 GROUP: Electrical DATE: September 06, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: Vehicle Theft Security System Alarm May Alert When Hood Is Opened OVERVIEW: This bulletin involves selectively erasing and reprogramming the Cabin Compartment Node Module (CCN) with new software. MODELS: 2007 (DR/DH/D1/DC) Ram Truck NOTE: This bulletin applies to vehicles equipped with a remote start system (sales code XBM) prior to October 10, 2006 (MDH 1010XX). SYMPTOM/CONDITION: The Vehicle Theft Security System (VTSS) may alert (flash lights and/or sound horn) if one of the following occurs: a. The customer arms the VTSS and then reaches through an open window, pulls on the hood release, and fully opens the vehicle hood. b. The customer releases the hood but not enough to open the hood ajar switch, arms the VTSS, and then fully opens the vehicle hood. c. The customer opens the hood, arms the VTSS, the vehicle communications bus goes in to "sleep mode" (may take 10 minutes), then the "LOCK" button on the key fob is depressed. The hood ajar switch is not part of the VTSS used on domestic use vehicles. The hood ajar switch is used for export vehicles equipped with the Vehicle Theft Alarm (VTA) system. DIAGNOSIS: 1. Connect the StarSCAN(R) to the vehicle. 2. Power up the StarSCAN(R) and obtain the HOME menu. 3. From the HOME menu select "ECU VIEW". 4. Select "CCN - Cabin Compartment". 5. Select "More Options". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 15126 6. Select "ECU Flash" 7. Read and record the software part number that is display with "Resident Flash File For Part". 8. Is the software part number 05172187AC (or later)? a. If YES >>> then STOP. This bulletin does not apply. Further diagnosis is required. b. If NO >>> then perform the Repair Procedure. NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the CCN in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash CCN" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 15127 13. Highlight the listed calibration. 14. Select "Update Controller". Follow on screen instructions. 15. When the CCN update is complete, select "OK". 16. Verify the part number at the top of the "Flash CCN" screen has updated to the new part number. NOTE: Due to the CCN programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 15128 Hood Sensor/Switch (For Alarm): Locations Component ID: 469 Component : SWITCH-HOOD AJAR Connector: Name : SWITCH-HOOD AJAR Color : # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 HOOD AJAR SWITCH SENSE G70 20VT/LB 2 AAT RETURN G930 20VT/TN Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 15129 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 15130 Hood Sensor/Switch (For Alarm): Diagrams Component ID: 469 Component : SWITCH-HOOD AJAR Connector: Name : SWITCH-HOOD AJAR Color : # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 HOOD AJAR SWITCH SENSE G70 20VT/LB 2 AAT RETURN G930 20VT/TN Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 15131 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Description Hood Sensor/Switch (For Alarm): Description and Operation Description DESCRIPTION The hood ajar switch is a normally closed, single pole, spring-loaded plunger actuated switch. This switch has two unique versions that are used in two different applications. One switch is used only on vehicles equipped with the Vehicle Theft Alarm (VTA) system for sale in certain export markets where protection of the underhood area is required equipment. The second switch is used only on domestic vehicles equipped with an optional remote starter system. The molded plastic switch body (5) has an integral molded connector receptacle (1) on the lower end containing two terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the headlamp and dash wire harness. Two integral latches (2) lock the switch into a keyed mounting hole in the stamped steel switch mounting bracket. The mounting bracket is secured with screws to the inboard side of the right front fender load beam within the engine compartment. A molded plastic striker secured to the underside of the hood panel inner reinforcement actuates the switch plunger as the hood panel is closed. The switch plunger (3) extends through a mounting collar (4) and a sleeve-like retainer ring on the upper end of the switch body. The retainer ring has a one time, self-adjustment feature that is activated after the switch is installed by closing the hood. The retainer ring is also color-coded to aid in identifying the switch application. A dark brown retainer ring identifies the underhood security switch application, while a white retainer ring identifies the remote starter system application. An installed hood ajar switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or requires readjustment, it must be replaced with a new unit. The hood ajar switch striker is not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced with a new unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Description > Page 15134 Hood Sensor/Switch (For Alarm): Description and Operation Operation OPERATION The hood ajar switches are interchangeable physically, but not functionally. In each case, the hood ajar switch is a normally closed switch that is held open as the spring-loaded switch plunger is depressed by the striker on the inner hood panel reinforcement when the hood panel is closed and latched. When the hood is opened, the spring-loaded switch plunger extends from the switch body and the switch contacts are closed. In the underhood security application (export vehicles only - dark brown retainer ring), the switch is connected in series between ground and the hood ajar switch sense input of the Totally Integrated Power Module (TIPM). The TIPM uses an internal resistor pull up to monitor the state of the hood ajar switch contacts. In the remote starter system application (domestic vehicles only - white retainer ring) the switch has a 1 kilo ohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between an output of the TIPM and the hood ajar switch sense input of the TIPM. The TIPM continually monitors this circuit and will store a Diagnostic Trouble Code (DTC) for any fault that it detects. The components of the switch self-adjustment feature include an integral stop on the shaft of the plunger and a ribbed, ratcheting sleeve-like retainer ring at the top of the switch body from which the plunger extends. With the switch mounting collar secured in its mounting bracket, the plunger is depressed by the striker on the hood inner reinforcement as the hood is closed. As the plunger is depressed, the plunger stop contacts the top of the retainer ring and it is driven downward, ratcheting through the switch mounting collar until the hood is fully closed and latched. The ribs on the retainer ring are engaged within the mounting collar to maintain this adjusted position. The hood ajar switch as well as the hard wired circuits between the switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between modules and other devices related to hood ajar switch operation that provide some features of the export vehicle theft or domestic remote starter systems. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to hood ajar switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal Hood Sensor/Switch (For Alarm): Service and Repair Removal Striker STRIKER NOTE: The hood ajar switch striker is not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Unlatch and open the hood. 2. Using a trim stick or another suitable wide flat-bladed tool, pry the rearward end of the hood ajar switch striker (2) away from the inner hood panel reinforcement (1) far enough to disengage the integral retainers from their mounting holes. 3. Remove the striker from the inner hood panel reinforcement and discard. Bracket BRACKET 1. Remove the hood ajar switch (2) from the mounting bracket (3). 2. Remove the two screws (4) that secure the hood ajar switch bracket to the two rivet nuts (1) in the right front load beam (6). 3. Remove the hood ajar switch mounting bracket from the inboard side of the right front load beam. Switch SWITCH Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal > Page 15137 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. From the top of the mounting bracket (3) on the right front load beam (6), squeeze the two hood ajar switch (2) latch tabs together and pull the switch upward. 4. Pull the hood ajar switch up through the hole in the mounting bracket far enough to access and disconnect the jumper wire harness connector (5) from the switch connector receptacle. 5. Remove the hood ajar switch from the mounting bracket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal > Page 15138 Hood Sensor/Switch (For Alarm): Service and Repair Installation Striker STRIKER NOTE: The hood ajar switch striker cap is not intended for reuse. If the striker cap is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Position the new hood ajar switch striker (2) to the mounting holes in the inner hood panel reinforcement (1) over the hood ajar switch (3). 2. Using hand pressure, press the hood ajar switch striker upward into the mounting holes in the inner hood panel reinforcement until both integral retainers are fully engaged. 3. Close and latch the hood. Bracket BRACKET 1. Check to be certain that the two rivet nuts (1) on the inboard side of the right front load beam (6) are in good condition and properly secured. 2. Position the hood ajar switch mounting bracket (3) onto the right front load beam. 3. Install and tighten the two screws (4) that secure the mounting bracket to the load beam. Beginning with the rearward screw, tighten both screws to 8 Nm (71 in. lbs.). 4. Reinstall the hood ajar switch (2) into the mounting bracket. Switch Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal > Page 15139 SWITCH 1. Position the hood ajar switch (2) near the hole in the mounting bracket (3) on the right front load beam (6). 2. Route the jumper wire harness connector (5) through the switch mounting bracket and reconnect it to the switch connector receptacle. 3. From the top of the mounting bracket, press the switch downward into the mounting hole until the integral switch latch tabs lock it into place. 4. Reconnect the battery negative cable. 5. Close and latch the hood. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Removal Body Emblem: Service and Repair Removal REMOVAL NAME PLATES NOTE: Mega Cab model shown in the illustration. Exterior name plates and decals for all other cab models are similar. Exterior name plate and decal usage vary by model. 1. As a guide for installation, apply a length of masking tape on the body (1), parallel to the top edge and, to one end of the name plate or decal (2) being removed. CAUTION: Do not exceed 52° C (120° F) when heating name plates, decals or body panels. Failure to follow this caution may result in damage to the name plates, decals and/or the vehicle paint finish. 2. If the temperature is below 21° C (70° F), warm the name plate or decal with a heat lamp or heat gun. NOTE: The exterior name plates are attached to the body with adhesive tape. 3. Using a trim stick C-4755 or equivalent, carefully remove the name plate or decal from the body panel, as necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Removal > Page 15145 Body Emblem: Service and Repair Installation INSTALLATION NAME PLATES NOTE: Mega Cab model shown in the illustration. Exterior name plates and decals for all other cab models are similar. Exterior name plate and decal usage vary by model. 1. Thoroughly clean all residue from the name plate or decal attachment areas of the body (1). 2. Wipe the attachment areas with a clean, lint-free cloth, moistened with a 50% solution of water and alcohol and then wipe dry the areas immediately with a dry, lint-free cloth. CAUTION: Do not exceed 52° C (120° F) when heating name plates, decals or body panels. Failure to follow this caution may result in damage to the name plates, decals and/or the vehicle paint finish. NOTE: If ambient temperatures are below 21° C (70° F), warm the name plate or decal and body panel with a heat lamp or gun to assure proper adhesion. 3. Remove the protective covering from the back of name plate or decal (2) and position the name plate or decal onto the body using the previously installed guide tape. NOTE: To ensure proper name plate or decal adhesion, apply consistent and uniform pressure of approximately 40 p.s.i. over the entire surface Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Removal > Page 15146 of each name plate or decal. 4. Install the name plate or decal onto the body. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Removal Lower Side Moulding / Trim: Service and Repair Removal REMOVAL NOTE: Quad Cab model shown in the illustration. Body side moldings for Regular cab models are similar. 1. As a guide for installation, apply a length of masking tape on the rocker panels (1), parallel to the top edge and, to one end of the body side molding (2 and 3) being removed CAUTION: Do not exceed 52° C (120° F) when heating the moldings or rocker panels. Failure to follow this caution may result in damage to the moldings and/or the vehicle paint finish. 2. If the temperature is below 21° C (70° F), warm the body side moldings with a heat lamp or heat gun. NOTE: The body side moldings are attached to the cab with adhesive tape. 3. Using a trim stick C-4755 or equivalent, carefully remove the moldings from the rocker panels, as necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Removal > Page 15151 Lower Side Moulding / Trim: Service and Repair Installation INSTALLATION NOTE: Quad Cab model shown in the illustration. Body side moldings for Regular cab models are similar. 1. Thoroughly clean all residue from the molding attachment areas of the rocker panels (1). 2. Wipe the attachment areas with a clean, lint-free cloth, moistened with a 50% solution of water and alcohol and then wipe dry the areas immediately with a dry, lint-free cloth. CAUTION: Do not exceed 52° C (120° F) when heating the moldings or rocker panels. Failure to follow this caution may result in damage to the moldings and/or the vehicle paint finish. NOTE: If ambient temperatures are below 21° C (70° F), warm the body side molding and rocker panel with a heat lamp or gun to assure proper adhesion. 3. Remove the protective covering from the back of the body side molding (2 and 3) and position the molding onto the rocker panel using the previously installed guide tape. NOTE: To ensure proper molding adhesion, apply consistent and uniform pressure of approximately 40 p.s.i. over the entire surface of each body side molding. 4. Install the body side molding onto the rocker panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Removal Front Fender Liner: Service and Repair Removal REMOVAL 1. Open the hood and disengage any wiring or component retaining clips from the front splash shield (4) (depending on application and shield being serviced). 2. Raise and support the vehicle. 3. Remove the eight screws (3) that secure the front splash shield to the fender rail (1) and the front fender (2). 4. Disconnect the front splash shield from the support bracket located on the front bumper and remove the splash shield. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Removal > Page 15158 Front Fender Liner: Service and Repair Installation INSTALLATION 1. Install the front edge of the front splash shield (4) into the support bracket located on the front bumper. 2. Position the front splash shield onto the fender rail (1) and the front fender (2). 3. Install the eight screws (3) that secure the front splash shield to the fender rail and the front fender. Tighten the screws to 5 Nm (44 in. lbs.). 4. Lower the vehicle and engage any wiring or component retaining clips to the front splash shield (depending on application and shield being serviced). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Fender > Rear Fender > System Information > Service and Repair > Removal Rear Fender: Service and Repair Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the tail lamp unit. 3. Remove the rear wheelhouse splash shield. 4. Remove the two marker lamp units from the rear fender. 5. Remove the two nuts (2) that secure the rear fender to the cargo box near the tail lamp opening (1). 6. Raise and support the vehicle. 7. Remove the two nuts (1) that secure the rear fender to the rear of the cargo box inner panel (2). 8. Remove the four bolts that secure the bottom edges of the rear fender to the cargo box. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Fender > Rear Fender > System Information > Service and Repair > Removal > Page 15163 9. Remove the four nuts (2) secure the front of the rear fender to the cargo box inner panel (1) 10. Loosen the three bolts (3) on each of the two fender support brackets (1) located on the cargo box outer panel (2). CAUTION: Prior to removing the rear fenders, mask off the surrounding cargo box areas to avoid damage to the cargo box painted surfaces. 11. Lift the rear fender straight up and off of the two support brackets and remove the fender. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Fender > Rear Fender > System Information > Service and Repair > Removal > Page 15164 Rear Fender: Service and Repair Installation INSTALLATION CAUTION: Prior to installing the rear fenders, mask off the surrounding areas to avoid damage to the cargo box painted surfaces. 1. Carefully position the rear fender onto the three bolts (3) on each of the two support brackets (1) located on the cargo box outer panel (2). 2. Install the four nuts (2) that secure the front of the rear fender to the cargo box inner panel (1). Tighten the nuts to 7 Nm (60 in. lbs.). 3. Install the two nuts (1) that secure the rear fender to the rear of the cargo box inner panel (2). Tighten the nuts to 7 Nm (60 in. lbs.). 4. Install the four bolts that secure the bottom edges of the rear fender to the cargo box. Tighten the bolts to 7 Nm (60 in. lbs.). 5. Tighten the three bolts on each of the two support brackets to 11 Nm (8 ft. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Fender > Rear Fender > System Information > Service and Repair > Removal > Page 15165 6. Lower the vehicle. 7. Install the two nuts (2) that secure the rear fender to the cargo box near the tail lamp opening (1). Tighten the nuts to 7 Nm (60 in. lbs.). 8. Install the two marker lamp units onto the rear fender. 9. Install the rear wheelhouse splash shield. 10. Install the tail lamp unit. 11. Reconnect the negative battery cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Removal Body / Frame Mount Bushing: Service and Repair Removal REMOVAL NOTE: Quad Cab model shown in the illustration. Body isolators for Regular cab models are similar. 1. Loosen all cab to frame mounting bolts (5) (six Regular cab, eight Quad Cab). 2. Remove the mounting bolts and rebound cushions (3) as necessary. NOTE: If servicing the rear isolators (2), remove the reinforcement plates (6) and the washers (4). 3. Using a floor jack and wooden block under the cab sill (1), lift the body to gain access to the isolators and remove the isolators as necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Removal > Page 15171 Body / Frame Mount Bushing: Service and Repair Installation INSTALLATION CAUTION: Whenever a body isolator bolt requires servicing or tightening, it is necessary to remove the bolt and install new thread locker compound to the threads. NOTE: Quad Cab model shown in the illustration. Body isolators for Regular cab models are similar. 1. Position the isolators (2) under the cab as necessary. CAUTION: If servicing the rear isolators, install the reinforcement plates (6) and the washers (4). 2. Lower the cab onto the isolators and install the mounting bolts (5) and rebound cushions (3) as necessary (six Regular cab, eight Quad Cab). 3. Tighten the mounting bolts to 81 Nm (60 ft. lbs.). bs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember - Removal Front Cross-Member: Service and Repair Front Crossmember - Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the front skid plate (2 - if equipped). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember - Removal > Page 15177 3. On the 2WD models, remove the bolts (2) and remove the crossmember (1). 4. On the 4WD models, remove the bolts (1) and remove the crossmember (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Front Crossmember - Removal > Page 15178 Front Cross-Member: Service and Repair Front Crossmember - Installation INSTALLATION 1. Install the crossmember (1). 2. Install the bolts (2); - On light duty 2WD vehicles, tighten the bolts to 61 Nm (45 ft. lbs.). - On heavy duty 2WD vehicles, tighten the bolts to 75 Nm (55 ft. lbs.). 3. On 4WD models, install the crossmember (2). 4. Install the bolts (1) and tighten to 102 Nm (75 ft. lbs.). 5. Install the front skid plate, if equipped (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal Rear Cross-Member: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the transfer case skid plate (if equipped). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal > Page 15183 3. Support the transmission (1) with a transmission jack (2) or suitable lifting device. 4. 2WD Vehicles - Remove the transmission mount nuts (3). 5. Remove the bolts and remove the crossmember (2). 6. 4WD Vehicles - Remove the transmission mount nuts (5). 7. Remove the bolts (3) and remove the crossmember (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal > Page 15184 Rear Cross-Member: Service and Repair Installation INSTALLATION 1. On Light Duty Vehicles, install the crossmember (2) and the bolts (4). Tighten the bolts to 102 Nm (75 ft. lbs.). 2. Install the transmission mount nuts and tighten to 54 Nm (40 ft. lbs.). 3. On Heavy Duty Vehicles, install the crossmember (4) and the bolts (3). Tighten the bolts to 115 Nm (85 ft. lbs.). 4. Install the transmission mount nuts and tighten to 54 Nm (40 ft. lbs.). 5. Remove the transmission support (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Removal > Page 15185 6. Install the transfer case skid plate (3 - if equipped). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Front Skid Plate Skid Plate: Service and Repair Front Skid Plate Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the bolts (3). 3. Slide skid plate (2) back off of the crossmember (1) and remove. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Front Skid Plate > Page 15190 1. Snap the rear tabs over the front crossmember (1) and install the skid plate (2). 2. Install the bolts (3) and tighten to 34 Nm (25 ft. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Front Skid Plate > Page 15191 Skid Plate: Service and Repair Transfer Case Skid Plate Removal REMOVAL 1. Raise and support the vehicle. 2. Support the skid plate (3) and remove the bolts (4). 3. Remove the skid plate (3). 4. Support the skid plate crossmember (2) and remove the bolts (1). 5. Remove the skid plate crossmember (2). Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Front Skid Plate > Page 15192 1. Install the skid plate crossmember (2) and bolts (1). 2. Tighten the bolts (1) to 34 Nm (25 ft. lbs.). 3. Install the skid plate (3) and bolts (4). 4. Tighten the bolts (4) to 34 Nm (25 ft. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Removal Trailer Hitch: Service and Repair Removal REMOVAL 1. Remove the rear bumper. 2. On Light Duty Vehicles, remove the hitch bolts (7) 3. On Heavy Duty Vehicles, remove the hitch bolts (8) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Removal > Page 15197 4. Disconnect all wire harness support push pins. 5. Remove the rear two cargo box bolts (3) and loosen the remaining bolts. 6. Using a suitable lifting device, lift and support the rear of the cargo box and remove the hitch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Removal > Page 15198 Trailer Hitch: Service and Repair Installation INSTALLATION 1. On Light Duty Vehicles, install the hitch (5) onto the frame rails and make sure the locators (1 and 2) on the inside of the hitch brackets are engaged with the holes in the top of the frame rails properly. 2. Install the hitch bolts (7) and tighten to 170 Nm (125 ft. lbs.). 3. Connect all wire harness support push pins. 4. On Heavy Duty Vehicles, install the hitch (5) onto the frame rails and make sure the locators (1 and 2) on the inside of the hitch brackets are engaged with the holes in the top of the frame rails properly. 5. Install the hitch bolts (8) and tighten to 170 Nm (125 ft. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Removal > Page 15199 6. Connect all wire harness support push pins. 7. Lower the cargo box and install the rear bolts (3). 8. Install the rear bumper. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Grille Grille: Service and Repair Grille Removal REMOVAL 1. Open the hood (2) and remove the six screws (5) that secure the grille (3) to the grille frame (4). 2. Remove the six nuts (1) that secure the grille to the hood and remove the grille. 3. If required, remove the grille frame from the hood. Installation INSTALLATION 1. If removed, install the grille frame (4). 2. Position and align the grille (3) onto the hood (2) 3. Install the six nuts (1) that secure the grille to the hood. Tighten the nuts to 5 Nm (44 in. lbs.). 4. Install the six screws (5) that secure the grille to the grille frame. Tighten the screws to 2.2 Nm (20 in. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Grille > Page 15204 Grille: Service and Repair Grille Frame Removal REMOVAL 1. Remove the grille. 2. Remove the six screws (3) that secure the grille frame (2) to the hood (1) and remove the frame. Installation INSTALLATION 1. Position the grille frame (2) onto the hood (1). 2. Install the six screws (3) that secure the grille frame to the hood. Tighten the screws to 5 Nm (44 in. lbs.). 3. Install the grille. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Removal Carpet: Service and Repair Removal REMOVAL NOTE: Carpet for Quad Cab model shown. Regular cab similar. 1. Remove the front seats. 2. If equipped, remove the floor console. 3. If equipped, remove the three bolts (1) that secure the rear storage compartment (2) to the floor panel (3) and remove the storage compartment from the rear trim panel (4). 4. On Quad Cab models, remove the rear seats (1). 5. On Quad Cab models, remove the rear cup holder (2) using a trim stick C-4755 or equivalent. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Removal > Page 15210 6. Remove the lower B-pillar trim panels. 7. On Quad Cab models, remove the bolt that secures the lower seat belt anchor to the floor panel near the B-pillars. 8. Remove the retaining screw (1) that secures the jack assembly (2) to the floor panel (3) and remove the jack assembly. 9. Remove the two bolts (4) that secure the jack assembly to the floor panel. 10. For trucks equipped with a scissor type jack, remove the bolts (1) and remove the jack (2). 11. Remove the screws and remove the load floor storage strap snaps (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Removal > Page 15211 12. On Quad Cab models, remove the eleven push-pin fasteners (1) that secure the rear of the carpet (2) to the floor panel (3). 13. Remove the carpet from the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Removal > Page 15212 Carpet: Service and Repair Installation INSTALLATION NOTE: Carpet for Quad Cab model shown. Regular cab similar. 1. Position the carpet (2) into the vehicle. 2. On Quad Cab models, install the eleven push-pin fasteners (1) that secure the carpet to the floor panel (3). 3. Install the load floor storage snaps and screws (1). 4. On trucks equipped with a scissor jack, install the jack and install the bolts (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Removal > Page 15213 5. Install the two bolts (4) that secure the jack assembly (2) to the floor panel (3). 6. Position the jack assembly onto the two bolts and install the retaining screw (1) . Tighten the screw securely. 7. On Quad Cab models, install the bolt that secures the lower seat belt anchors the floor panel near the B-pillars. Tighten the bolt to 40 Nm (30 ft. lbs.). 8. Install the lower B-pillar trim panels. 9. On Quad Cab models, install the rear seat (1). 10. On Quad Cab models, install the rear cup holder (2). 11. If equipped, position the rear storage compartment (2) onto the rear cab trim panel (4) and install the three bolts (1). Tighten the bolts to 6 Nm (55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Removal > Page 15214 in. lbs.). 12. If equipped, install the floor console. 13. Install the front seats. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams Console Lamp: Diagrams Component ID: 158 Component : LAMP-CENTER CONSOLE Connector: Name : LAMP-CENTER CONSOLE Color : # of pins : 2 Qualifier : (LOWER BUCKET) Gender : FEMALE Pin Description Circuit 1 GROUND Z939 18BK 2 GLOVE BOX LAMP DRIVER M228 18YL/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation Air Bag(s) Arming and Disarming: Technical Service Bulletins Air Bag System - Passenger Air Bag Deactivation NUMBER: 08-001-07 REV. B GROUP: Electrical DATE: May 16, 2007 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED. THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION. DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION. SUBJECT: Passenger Air Bag Deactivation MODELS: 2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 0300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakoka 2006 - 2007 (DR) Ram Truck 2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 15224 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet. NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States. PARTS REQUIRED: POLICY: Information Only Disclaimer: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 15225 This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Removal Drink Holders: Service and Repair Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Removal > Page 15230 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Removal > Page 15231 Drink Holders: Service and Repair Installation INSTALLATION 1. Position the cup holder (2) onto the clips (1) and seat fully. 2. Install the screws (2). 3. Position the bezel and seat the clips fully. 4. Install the floor console if necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box Door Latch - Removal Glove Compartment: Service and Repair Glove Box Door Latch - Removal REMOVAL 1. Remove the glove box and place it on a workbench. 2. Remove the 15 screws (1) that secure the glove box bin (2) and the inner glove box door panel (3) to the outer glove box door panel (4). 3. Remove the glove box bin and the inner glove box door panel from the outer glove box door panel. 4. Remove the two screws (1) that secure the glove box latch (2) to the outer glove box door panel (3) and remove the latch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box Door Latch - Removal > Page 15236 Glove Compartment: Service and Repair Glove Box Door Latch - Installation INSTALLATION 1. Position the glove box latch (2) into the outer glove box door panel (3). 2. Install the two screws (1) that secure the glove box latch to the outer glove box door panel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Position the inner glove box door panel (3) and the glove box bin (2) onto the outer glove box door panel (4). 4. Install the fifteen screws (1) that secure the inner glove box door panel and the glove box bin to the outer glove box door panel. Tighten the screws to 2 Nm (17 in. lbs.). 5. Install the glove box. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box Door Latch - Removal > Page 15237 Glove Compartment: Service and Repair Instrument Panel Glove Box - Removal REMOVAL 1. Open the glove box (1). 2. Release the two glove box stops (2) and lower the glove box downward past the stops. 3. Disengage the glove box hinges from the instrument panel and remove the glove box. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box Door Latch - Removal > Page 15238 Glove Compartment: Service and Repair Instrument Panel Glove Box - Installation INSTALLATION 1. Engage the hinges of the glove box (1) to the instrument panel. 2. Press downward on the back edge of the glove box bin and raise the glove box past the two stops (2). 3. Close the glove box. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Removal Headliner: Service and Repair Removal REMOVAL NOTE: Headliner for Quad Cab model shown. Regular cab similar. 1. On Mega Cab models, remove the front seats. 2. Remove the A-pillar trim panels. 3. Remove the upper B-pillar trim panels. 4. On Quad Cab models, remove the upper C-pillar trim panels. 5. Disconnect the wire harness connector (1) located at the left A-pillar from the headliner wire harness (2). 6. Disconnect the headliner wire harness connector (3) from the inside rear view mirror. 7. Remove the overhead console. 8. Remove the sun visors (4). 9. Remove the sun visor supports (5). 10. Remove the dome lamp (6). 11. Remove the two coat hooks (7). 12. Lower the rear of the headliner (9) downward from the roof panel (10) and disconnect the headliner wire harness connector (8) from the center high mounted stop lamp. 13. Lower the front of the headliner downward and remove the headliner through the passenger door opening. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Removal > Page 15243 Headliner: Service and Repair Installation INSTALLATION NOTE: Headliner for Quad Cab model shown. Regular cab similar. 1. Position the headliner (9) into the vehicle through the passenger door opening. 2. Connect the headliner wire harness connector (8) to the center high mounted stop lamp. 3. Raise the rear of the headliner upward and install the two coat hooks (7). 4. Raise the front of the headliner upward and install the sun visor supports (5). 5. Install the sun visors (4). 6. Install the dome lamp (6). 7. Install the overhead console. 8. Connect the headliner wire harness connector (3) to the inside rear view mirror 9. Connect the headliner wire harness (2) to the wire harness connector (1) located at the left A-pillar. 10. On Quad Cab models, install the upper C-pillar trim panel. 11. Install the upper B-pillar trim panels. 12. Install the upper A-pillar trim panels. 13. On Mega Cab models, install the front seats. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair > A-Pillar Trim/Grab Handle Passenger Assist Handle: Service and Repair A-Pillar Trim/Grab Handle Removal REMOVAL 1. Using a small flat-bladed tool, carefully open the two fastener covers (3) located in the a-pillar trim panel (2). 2. Remove the two bolts (4) that secure the a-pillar trim panel to the a-pillar (1) and remove the trim panel. Installation INSTALLATION 1. Position the locating tab of the A-pillar trim panel (2) into the slot located in the top of the instrument panel. 2. Install the A-pillar trim panel onto the A-pillar (1) and install the two bolts (4). Tighten the bolts to 6 Nm (55 in. lbs.). 3. Close the two fastener covers (3) located in the A-pillar trim panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair > A-Pillar Trim/Grab Handle > Page 15248 Passenger Assist Handle: Service and Repair B-Pillar Grab Handle Removal REMOVAL 1. Using a small flat-bladed tool, carefully open the two fastener covers (2) located on the grab handle (1). 2. Remove the two bolts (3) that secure the grab handle to the B-pillar and remove the grab handle. Installation INSTALLATION 1. Install the grab handle (1) onto the B-pillar and install the two bolts (3). Tighten the bolts to 6 Nm (55 in. lbs.). 2. Close the two fastener covers (2) located on the grab handle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Removal Scuff Plate: Service and Repair Removal REMOVAL 1. Using a trim stick C-4755 or equivalent, disengage the retaining tabs of the sill trim panel (1) from the retainer clips in the rear door sill (2) and remove the trim panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Removal > Page 15253 Scuff Plate: Service and Repair Installation INSTALLATION 1. Position the sill trim panel (1) onto the rear door sill (2). 2. Engage the retaining tabs that secure the sill trim panel to the rear door sill. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Sun Visor Sun Visor: Service and Repair Sun Visor Removal REMOVAL 1. Remove the three screws (1) that secure each sun visor (2) to the roof panel and remove the visor from the headliner (3). 2. If equipped, disconnect the wire harness connector for the illuminated vanity mirror (4). Installation INSTALLATION 1. If equipped, connect the wire harness connector for the illuminated vanity mirror (4). 2. Position the sun visor (2) onto the headliner (3). 3. Install the three screws (1) that secure each sun visor to the roof panel. Tighten the screws to 2.2 Nm (20 in. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Sun Visor > Page 15258 Sun Visor: Service and Repair Sun Visor Support Removal REMOVAL 1. Using a trim stick C-4755 or equivalent, disengage the release clip (3) as shown and remove the sun visor support (1) from the headliner (2) Installation INSTALLATION 1. Position the sun visor support (1) through the headliner (2) and fully seat the base of the support to the roof panel. 2. Engage the release clip (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures Trim Panel: Procedures HEAT STAKING 1. Remove trim panel. 2. Bend or move the trim panel components at the heat staked joints. Observe the heat staked locations and/or component seams for looseness. 3. Heat stake the components. a. If the heat staked or component seam location is loose, hold the two components tightly together and using a soldering gun with a flat tip, melt the material securing the components together. Do not over heat the affected area, damage to the exterior of the trim panel may occur. b. If the heat staked material is broken or missing, use a hot glue gun to apply new material to the area to be repaired. The panels that are being heat staked must be held together while applying the glue. Once the new material is in place, it may be necessary to use a soldering gun to melt the newly applied material. Do not over heat the affected area, damage to the exterior of the trim panel may occur. 4. Allow the repaired area to cool and verify the repair. 5. Install trim panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 15263 Trim Panel: Removal and Replacement Removal REMOVAL 1. Remove the rear cab trim panel. 2. Disengage the retaining tabs (1) that secure the body vent (3) to the cab back panel (2). 3. Remove the vent through the opening in the cab back panel. Installation INSTALLATION 1. Position the body vent (3) into the opening of the cab back panel (2). 2. Install the body vent into the cab back panel and fully engage the retaining tabs (1). 3. Install the rear cab trim panel. Coat Hook - Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 15264 1. Using a trim stick C-4755 or equivalent, disengage the release clip (2) as shown and remove the coat hook (1) from the headliner (3) Coat Hook - Installation INSTALLATION 1. Position the coat hook (1) through the headliner (3) and fully seat the base of the support to the roof panel. 2. Engage the release clip (2). Cowl Trim - Removal REMOVAL 1. Using a trim stick C-4755 or equivalent, disengage the retaining tabs of the cowl trim panel (1) from the retainer clips (2) in the door sill (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 15265 2. Pull the cowl trim panel rearward and remove it from the vehicle. Cowl Trim - Installation INSTALLATION 1. Position the cowl trim panel (1) onto the door sill (3). 2. Push the cowl trim panel forward and then engage the retaining tabs that secure the sill trim panel to the rear door sill. Front Door Trim Panel - Removal REMOVAL 1. Remove the screw (1) that secures the interior door handle (2) to the interior door handle actuator (3). 2. Remove the interior door handle from the interior door handle actuator. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 15266 3. If equipped, remove the manual window crank (1) using a window crank removal tool (2). 4. Remove the two screws (2) that secure the door trim panel (3) to the two screw inserts (1). 5. Remove the two screws (4) that secure the door trim panel to the bottom of the door. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. 6. Lift the door trim panel straight upward to disconnect the molded plastic retaining clips (5) from the door. 7. If equipped, disconnect the door wire harness from the power door switch assembly and remove the door trim panel. Front Door Trim Panel - Installation INSTALLATION 1. If equipped, connect the door wire harness to the power door switch assembly. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not force the door trim panel onto the door or damage to the trim panel and/or the power switch assembly will occur. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 15267 2. Position the door trim panel (3) and align the molded plastic retaining clips (5) to the door. 3. Push the door trim panel straight downward until all of the retaining clips are fully engaged to the door. 4. Install the two screws (2) that secure the door trim panel to the two screw inserts (1). 5. Install the two screws (4) that secure the door trim panel to the bottom of the door. 6. If equipped, install the manual window crank. 7. Position the interior door handle (2) onto the interior door handle actuator (3). 8. Install the screw (1) that secures the interior door handle to the interior door handle actuator. Tighten the screw securely. Load Floor - Removal REMOVAL 1. Move the rear seat cushion (1) to the up position. 2. Remove the two nuts (2) that secure the rear of the load floor (3) to the floor panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 15268 3. Move the load floor (2) to the up position. 4. Remove the two bolts (3) that secure the load floor to the floor panel (1) and remove the load floor. 5. If required, remove the support cylinder (4). Load Floor - Installation INSTALLATION 1. If removed, install the load floor support cylinder (4). 2. Position the load floor (2) into the vehicle and install the two bolts (3) that secure it to the floor panel (1). Tighten the bolts to 40 Nm (30 ft. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 15269 3. Move the load floor (3) to the down position and install the two nuts (2) that secure the load floor to the floor panel. Tighten the nuts to 25 Nm (18 ft. lbs.). 4. Move the rear seat cushion (1) to the down position. Removal REMOVAL REGULAR CAB 1. Remove the cowl trim panel. 2. Remove the upper B-pillar trim panel. 3. Remove the bolt (2) that secures the seat belt (1) to the bottom of the B-pillar (4) and position the seat belt out of the way. 4. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the lower B-pillar trim panel (3) to the B-pillar. 5. Remove the seat belt from the lower B-pillar trim panel through the slot provided and remove the trim panel. QUAD CAB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 15270 6. Remove the cowl trim panel. 7. Remove the rear door sill trim cover. 8. Remove the upper B-pillar trim panel. 9. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the lower B-pillar trim panel (1) to the B-pillar (2). 10. Remove the seat belt (3) from the lower B-pillar trim panel through the slot provided and remove the trim panel. Installation INSTALLATION REGULAR CAB 1. Route the seat belt (1) through the slot in the lower B-pillar trim panel (3) and position the trim panel to the B-pillar (4). 2. Engage the retaining tabs that secure the lower B-pillar trim panel to the B-pillar. 3. Install the bolt (2) that secures the seat belt to the bottom of the B-pillar. Tighten the bolt to 40 Nm (30 ft. lbs.). 4. Install the upper B-pillar trim panel. 5. Install the cowl trim panel. QUAD CAB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 15271 6. Route the seat belt (3) through the slot in the lower B-pillar trim panel (1) and position the trim panel to the B-pillar (2). 7. Engage the retaining tabs that secure the lower B-pillar trim panel to the B-pillar. 8. Install the upper B-pillar trim panel. 9. Install the rear door sill trim cover. 10. Install the cowl trim panel. Removal REMOVAL REGULAR CAB 1. Remove the cap (1) and then the bolt (2) that secures the seat belt (3) to the top of the B-pillar (4) and position the seat belt out of the way. 2. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the upper B-pillar trim panel (5) to the B-pillar and remove the trim panel. QUAD CAB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 15272 3. Using a small flat-bladed tool, carefully open the two fastener covers (2) located on the grab handle (1). 4. Remove the two bolts (3) that secure the grab handle to the B-pillar and remove the grab handle. 5. Remove the cap (1) and the bolt (2) that secures the seat belt (3) to the top of the B-pillar (4) and position the seat belt out of the way. 6. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the upper B-pillar trim panel (5) to the B-pillar and remove the trim panel. Installation INSTALLATION REGULAR CAB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 15273 1. Position the upper B-pillar trim panel (5) to the B-pillar (4). 2. Engage the retaining tabs that secure the upper B-pillar trim panel to the B-pillar. 3. Install the bolt (2) that secures the seat belt (3) to the top of the B-pillar. Tighten the bolt to 40 Nm (30 ft. lbs.). 4. Install the cap (1) onto the seat belt. QUAD CAB 5. Position the upper B-pillar trim panel (5) to the B-pillar (4). 6. Engage the retaining tabs that secure the upper B-pillar trim panel to the B-pillar. 7. Install the bolt (2) that secures the seat belt (3) to the top of the B-pillar. Tighten the bolt to 40 Nm (30 ft. lbs.). 8. Install the cap (1) onto the seat belt. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 15274 9. Install the grab handle (1) onto the B-pillar and install the two bolts (3). Tighten the bolts to 6 Nm (55 in. lbs.). 10. Close the two fastener covers (2) located on the grab handle. Removal REMOVAL 1. Remove the upper C-pillar trim panel. 2. Remove the bolt (3) that secures the seat belt (2) to the bottom of the C-pillar (4) and position the seat belt out of the way. 3. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the lower C-pillar trim panel (1) to the C-pillar. 4. Remove the seat belt from the lower C-pillar trim panel through the slot provided and remove the trim panel. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 15275 1. Route the seat belt (2) through the slot in the lower C-pillar trim panel (1) and position the trim panel to the C-pillar (4). 2. Engage the retaining tabs that secure the lower C-pillar trim panel to the C-pillar. 3. Install the bolt (3) that secures the seat belt to the bottom of the C-pillar. Tighten the bolt to 40 Nm (30 ft. lbs.). 4. Install the upper C-pillar trim panel. Removal REMOVAL 1. Remove the cap (1) and then the bolt (2) that secures the seat belt (3) to the top of the C-pillar (4) and position the seat belt out of the way. 2. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the upper C-pillar trim panel (5) to the C-pillar and remove the trim panel. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 15276 1. Position the upper C-pillar trim panel (5) to the C-pillar (4). 2. Engage the retaining tabs that secure the upper C-pillar trim panel to the C-pillar. 3. Install the bolt (2) that secures the seat belt (3) to the top of the C-pillar. Tighten the bolt to 40 Nm (30 ft. lbs.). 4. Install the cap (1) onto the seat belt. Removal REMOVAL 1. If equipped, remove the three bolts (1) that secure the rear storage compartment (2) to the floor panel (3) and remove the storage compartment from the rear cab trim panel (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 15277 2. If equipped, using a trim stick C-4755 or equivalent, disengage the latch (4) for the utility hook cover (3) and open the cover to gain access to the screw (1) that secures the utility hook (2) to the rear cab back panel. 3. On Regular cab models, remove the lower B-pillar trim panels. 4. On Regular cab models, remove the utility hook (3) or the storage bin latch (4) (depending on application) from the rear cab trim panel (1) and remove the trim panel. 5. On Quad Cab models, remove the child seat tether straps from the rear cab back panel (2). 6. On Quad Cab models, remove the center seat belt trim bezel. 7. On Quad Cab models, remove the lower C-pillar trim panels. 8. On Quad Cab models, remove the two push-pin fasteners (1 and 4) that secure the rear cab trim panel (3) to the rear cab back panel and remove the trim panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 15278 Installation INSTALLATION 1. On Quad Cab models, position the rear cab trim panel (3) onto the rear cab back panel (2) and install the two push-pin fasteners (1 and 4). 2. On Quad Cab models, install the lower C-pillar trim panels. 3. On Quad Cab models, install the center seat belt trim beze. 4. On Quad Cab models, install the child seat tether straps. 5. On Regular cab models, position the rear cab trim panel (1) onto the rear cab back panel (2) and install the utility hook (3) or the storage bin latch (4) (depending on application). 6. On Regular cab models, install the lower B-pillar trim panels. 7. If equipped, position the rear storage compartment (2) onto the rear cab trim panel (4) and install the three bolts (1). Tighten the bolts to 6 Nm (55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 15279 in. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Under Seat Storage Bin Lid Utility Storage Compartment: Service and Repair Under Seat Storage Bin Lid Removal REMOVAL NOTE: Do not reuse the seat fasteners, always replace with new ones. 1. Open the center seat cushion/storage bin. 2. Position the seat cushion cover aside, remove the hinge bolts (2) and discard. 3. Remove the seat cushion (4). Installation INSTALLATION NOTE: Do not reuse the seat fasteners, always replace with new ones. 1. Position the center seat cushion (4) on the hinges (3) and install new bolts (2). 2. Tighten the bolts (2) to 20 Nm (15 ft. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Under Seat Storage Bin Lid > Page 15284 3. Position the cushion cover back over the hinges. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Under Seat Storage Bin Lid > Page 15285 Utility Storage Compartment: Service and Repair Under Seat Storage Bin Removal REMOVAL 1. Remove the amplifier, if equipped. 2. Remove the center seat cushion. 3. Remove the six screws and remove the bin. Installation INSTALLATION 1. Install the bin over the seat cushion hinges and install the six screws. 2. Install the center seat cushion. 3. Install the amplifier, if equipped. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Under Seat Storage Bin Lid > Page 15286 Utility Storage Compartment: Service and Repair Under Seat Storage Bin Covering Removal REMOVAL 1. Remove the under seat storage bin. 2. Disconnect the j-straps and remove the cover. Installation INSTALLATION 1. Install the storage bin cover and connect the j-straps. 2. Install the under seat storage bin. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair > Under Seat Storage Bin Lid > Page 15287 Utility Storage Compartment: Service and Repair Under Seat Storage Bin Latch Removal REMOVAL 1. Open the under seat storage bin. 2. Remove the two screws and remove the latch assembly. Installation INSTALLATION 1. Install the latch assembly and install the screws. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Removal Door Lock Cylinder: Service and Repair Removal REMOVAL 1. Remove the exterior door handle (1). 2. Remove the clip (3) that secures the lock cylinder lever (5) and the electric lock switch (4), if equipped, to the door lock cylinder (6). 3. Remove the screw (2) that secures the door lock cylinder to the exterior handle and remove the lock cylinder. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Removal > Page 15294 Door Lock Cylinder: Service and Repair Installation INSTALLATION 1. Position the door lock cylinder (6) into the exterior door handle (1). 2. Install the screw (2) that secures the door lock cylinder to the exterior door handle. Tighten the screw securely. 3. Install the electric lock switch (4), if equipped, and the lock cylinder lever (5) to the door lock cylinder. 4. Install the clip (3) that secures the lock cylinder lever and the electric lock switch, if equipped, to the door lock cylinder. 5. Install the exterior door handle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Component ID: 211 Component : MODULE-SENTRY KEY REMOTE ENTRY Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z109 20BK/GY 5 FUSED B(+) A114 18GY/RD 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT 8-Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 15299 Component Location - 41 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 15300 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 15301 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 15302 Keyless Entry Module: Diagrams Component ID: 211 Component : MODULE-SENTRY KEY REMOTE ENTRY Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z109 20BK/GY 5 FUSED B(+) A114 18GY/RD 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT 8-Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 15303 Component Location - 41 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 15304 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 15305 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry Keyless Entry Module: Description and Operation Module-Remote Keyless Entry Description DESCRIPTION When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 Km/h(15 mph) will also cancel the panic event. Operation OPERATION Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 15308 Keyless Entry Module: Description and Operation Sentry Key Remote Entry Module Description DESCRIPTION The Sentry Key REmote Entry Module (SKREEM) (1) is sometimes referred to as the Wireless Control Module (WCM). The SKREEM is the primary component of the Sentry Key Immobilizer System (SKIS). It is also the receiver for the Remote Keyless Entry (RKE) system. The SKREEM is located on the right side of the steering column, near the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM has an integral molded plastic halo-like antenna ring (4) that extends from the bottom. When the SKREEM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle (3) is located just behind the antenna ring on the bottom of the SKREEM housing. An integral molded plastic mounting tab (2) on the rear corner of the SKREEM housing has a hole in the center through which a screw passes to secure the unit to the steering column. The SKREEM is connected to the vehicle electrical system through a single take out and connector of the instrument panel wire harness. Two SKREEM modules are used: one for vehicles equipped with RKE only, and one for vehicles equipped with RKE and SKIS. The SKREEM cannot be adjusted or repaired. If ineffective or damaged, the entire SKREEM unit must be replaced. Operation OPERATION The Sentry Key REmote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver. The SKREEM communicates over the Controller Area Network (CAN) data bus with the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), the Powertrain Control Module (PCM)/Engine Control Module (ECM) or the diagnostic scan tool. The SKREEM and the PCM/ECM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS) disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKREEM or the PCM/ECM. However, the use of this strategy also means that replacement of either the SKREEM or the PCM/ECM units will require a system initialization procedure to restore system operation. The SKREEM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM. For added system security, each SKREEM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM or ECM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM. Therefore, the Secret Key code is a common element that is found in every component of the SKIS. Another security code called a PIN, is used to gain access to the SKREEM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKREEM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM or ECM during SKIS initialization. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 15309 In the event that a SKREEM replacement is required, the Secret Key code can be transferred to the new SKREEM from the PCM or ECM using a diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the ON position, the SKREEM transmits an RF signal to excite the transponder in the ignition key. The SKREEM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM sends an electronic valid key message to the PCM/ECM over the CAN bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the SKREEM sends an invalid key message to the PCM/ECM. The PCM/ECM will enable or disable engine operation based upon the status of the SKREEM messages. It is important to note that the default condition in the PCM or ECM is an invalid key; therefore, if no message is received from the SKREEM by the PCM or ECM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM also sends security indicator request messages to the EMIC over the CAN data bus to tell the EMIC how to operate the security indicator. The security indicator request message from the SKREEM tells the EMIC to turn the indicator ON for about three seconds each time the ignition switch is turned to the ON position as a bulb test. After completion of the bulb test, the SKREEM sends security indicator request messages to the EMIC to turn the indicator OFF, turn the indicator ON, or to flash the indicator ON and OFF. If the security indicator flashes or stays ON solid after the bulb test, it signifies a SKIS fault. If the SKREEM detects a system malfunction or the SKIS has become ineffective, the security indicator will stay ON solid. If the SKREEM detects an invalid key or if a key transponder-related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM will also send messages to the EMIC to flash the security indicator whenever the Customer Learn programming mode is being utilized. The SKIS performs a self-test each time the ignition switch is turned to the ON position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM memory if a system malfunction is detected. The hard wired circuits of the SKREEM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SKREEM or the electronic controls or communication between other modules and devices that provide some features of the SKIS. The most reliable, efficient, and accurate means to diagnose the SKREEM or the electronic controls and communication related to SKREEM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Description and Operation > Page 15310 Keyless Entry Module: Testing and Inspection REMOTE KEYLESS ENTRY MODULE The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Removal Keyless Entry Module: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, push inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 15313 8. Disconnect the wire harness connector (2) from the Sentry Key REmote Entry Module (SKREEM) (1). 9. Remove the screw (3) that secures the SKREEM (1) to the steering column (2). 10. Disengage the antenna ring from around the ignition lock cylinder housing and remove the SKREEM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 15314 Keyless Entry Module: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the Sentry Key REmote Entry Module (SKREEM) (1) onto the steering column (2) with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw (3) that secures the SKREEM to the steering column housing. Tighten the screw to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the SKREEM (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 15315 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). 10. Reconnect the battery negative cable. NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS) if the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start Antenna > Component Information > Technical Service Bulletins > Remote Start System - Antenna Diagnostic Chart Keyless Start Antenna: Technical Service Bulletins Remote Start System - Antenna Diagnostic Chart NUMBER: 08-003-07 GROUP: Electrical DATE: January 27, 2007 SUBJECT: Remote Start System - Diagnostic Chart For Antenna OVERVIEW: This bulletin involves a diagnostic chart that may be used to aid the technician with the diagnosis of the antenna on an originally equipped (factory installed) remote start system. MODELS: 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) 2006-2007 (HB/HG) Durango/Aspen 2007 (JS) Sebring/Avenger 2007 (KA) Nitro 2007 (ND) Dakota 2007 (WK) Grand Cherokee 2007 (XK) Commander NOTE: This bulletin applies to vehicles with an original equipment Remote Start system (sales code XBM). DISCUSSION: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start Antenna > Component Information > Technical Service Bulletins > Remote Start System - Antenna Diagnostic Chart > Page 15321 The customer may notice that the signal range of the Remote Keyless Entry (RKE) system is reduced. The RKE key fob may need to be closer than 3 meters (10 feet) before the functions available on the key fob will operate. This condition may be due to the RKE antenna. The diagnostic flow chart is provide as a diagnostic aid for dealer technician (Fig. 1). POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Specifications Keyless Entry Transmitter: Specifications REMOTE KEYLESS ENTRY TRANSMITTER RANGE Normal operation range is up to a distance of 3 to 7 meters (10 to 23 ft.) of the vehicle. Range may be better or worse depending on the environment around the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Component Tests and General Diagnostics Keyless Entry Transmitter: Component Tests and General Diagnostics REMOTE KEYLESS ENTRY TRANSMITTER Using special tool 9001, first test to ensure that the transmitter is functioning. Typical testing distance is 2.5 centimeters (1 inch) for Asian transmitters and 30.5 centimeters (12 inches) for all others. To test, position the transmitter as shown. Press any transmitter button, then test each button individually. The tool will beep if a radio signal strength that lights five or more LED's is detected. Repeat this test three times. If transmitter fails any of the test refer to the Diagnostic Procedures information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 15327 Keyless Entry Transmitter: Programming and Relearning STANDARD PROCEDURE - RKE TRANSMITTER PROGRAMING New Remote Keyless Entry (RKE) transmitters can be programed using the scan tool and the proper Diagnostic Procedures manual. The scan tool can provide confirmation that the PCI data bus is functional, and that all of the electronic modules are sending and receiving the proper messages on the PCI data bus. The following procedure can be used as long as one programmed transmitter is available: NOTE: When entering program mode using that programmed fob, ALL currently programmed fobs will be erased and they will have to be reprogrammed for the vehicle. If program mode is entered and no action is performed, the previously programmed fobs will continue to function. 1. Enter the vehicle and close all doors. 2. Fasten the seat belt (this will cancel the seat belt chime). Turn the ignition to the RUN position. 3. Press and hold the UNLOCK button on a programmed transmitter for 4 to 10 seconds. Within the 4 to 10 seconds with the UNLOCK button still depressed, press the PANIC button for one second. When a single chime is heard, release both buttons. The chime indicates the system is in program mode. 4. Press and release both the LOCK and UNLOCK buttons simultaneously on a fob to be programmed. A single chime will be heard, this indicates the fob has been recognized. 5. Press and release any button on the same fob. A single chime will be heard, this indicates the fob has been programmed. 6. Repeat steps 4 and 5 for up to a total of 4 fobs. 7. Turn the ignition OFF. 8. Turn the ignition ON or wait 60 seconds. The vehicle will remain in program mode for up to 60 seconds from when the original chime (step 3) was heard. After 60 seconds, all programmed transmitters will function normally. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Page 15328 Keyless Entry Transmitter: Service and Repair STANDARD PROCEDURE - RKE TRANSMITTER BATTERIES NOTE: Do not disturb the metal terminal near the batteries. Avoid touching the new batteries. Skin oils may cause battery deterioration. If batteries are touched, clean with rubbing alcohol. The Remote Keyless Entry (RKE) transmitter case snaps open and shut for battery access. To replace the RKE transmitter batteries: 1. Using a thin coin, gently pry at the notch in the center seam of the RKE transmitter case halves near the key ring until the two halves unsnap. Be careful not to damage the rubber gasket when separating the case halves. 2. Lift the back half of the transmitter case off of the RKE transmitter. 3. Remove the two batteries from the RKE transmitter. 4. Replace the two batteries with new 3V lithium 2016 cell. Install the batteries with the positive terminal up. Reference the "+ SIDE UP" on the inside of the bottom half of the transmitter case. 5. Align the two RKE transmitter case halves with each other, and squeeze them firmly and evenly together until they snap back into place. Test transmitter operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver Power Door Lock Actuator: Locations Latch-Door-Driver Component ID: 189 Component : LATCH-DOOR-DRIVER Connector: Name : LATCH-DOOR-DRIVER Color : BLACK # of pins : 2 Qualifier : (BASE) Pin Description Circuit 1 DRIVER DOOR AJAR SWITCH SENSE G75 20VT 2 GROUND Z917 20BK Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 15334 Connector: Name : LATCH-DOOR-DRIVER Color : BLACK # of pins : 4 Qualifier : (POWER LOCKS) Pin Description Circuit 1 DRIVER DOOR AJAR SWITCH SENSE G75 20VT 2 GROUND Z917 20BK 3 DOOR UNLOCK DRIVER LEFT FRONT P1 18TN/LG 4 DOOR LOCK DRIVER LEFT DOORS P393 18LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 15335 Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 15336 Power Door Lock Actuator: Locations Latch-Door-Left Rear Component ID: 190 Component : LATCH-DOOR-LEFT REAR Connector: Name : LATCH-DOOR-LEFT REAR Color : BLACK # of pins : 2 Qualifier : (BASE) Pin Description Circuit 1 LEFT REAR DOOR AJAR SWITCH SENSE G77 20VT/GY 2 GROUND Z917 20BK Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 15337 Connector: Name : LATCH-DOOR-LEFT REAR Color : BLACK # of pins : 4 Qualifier : (POWER LOCKS) Pin Description Circuit 1 LEFT REAR DOOR AJAR SWITCH SENSE G77 20VT/GY 2 GROUND Z917 20BK 3 DOOR UNLOCK DRIVER LEFT REAR P5 18TN/OR 4 DOOR LOCK DRIVER LEFT DOORS P393 18LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 15338 Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 15339 Power Door Lock Actuator: Locations Latch-Door-Passenger Component ID: 191 Component : LATCH-DOOR-PASSENGER Connector: Name : LATCH-DOOR-PASSENGER Color : BLACK # of pins : 2 Qualifier : (BASE) Pin Description Circuit 1 DRIVER DOOR AJAR SWITCH SENSE G74 20VT 2 GROUND Z917 20BK Component Location - 56 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 15340 Connector: Name : LATCH-DOOR-PASSENGER Color : BLACK # of pins : 4 Qualifier : (POWER LOCKS) Pin Description Circuit 1 PASSENGER DOOR AJAR SWITCH SENSE G74 20VT/WT 2 GROUND Z917 20BK 3 DOOR UNLOCK DRIVER RIGHT DOORS G778 18VT/LB 4 DOOR LOCK DRIVER RIGHT DOORS P392 18LG/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 15341 Component Location - 56 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 15342 Power Door Lock Actuator: Locations Latch-Door-Right Rear Component ID: 192 Component : LATCH-DOOR-RIGHT REAR Connector: Name : LATCH-DOOR-RIGHT REAR Color : BLACK # of pins : 2 Qualifier : (BASE) Pin Description Circuit 1 RIGHT REAR DOOR AJAR SWITCH SENSE G76 20VT/GY 2 GROUND Z917 20BK Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 15343 Connector: Name : LATCH-DOOR-RIGHT REAR Color : BLACK # of pins : 4 Qualifier : (POWER LOCKS) Pin Description Circuit 1 RIGHT REAR DOOR AJAR SWITCH SENSE G76 20VT/GY 2 GROUND Z917 20BK 3 DOOR UNLOCK DRIVER RIGHT DOORS G778 18TN/OR 4 DOOR LOCK DRIVER RIGHT DOORS P392 18LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Latch-Door-Driver > Page 15344 Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver Power Door Lock Actuator: Diagrams Latch-Door-Driver Component ID: 189 Component : LATCH-DOOR-DRIVER Connector: Name : LATCH-DOOR-DRIVER Color : BLACK # of pins : 2 Qualifier : (BASE) Pin Description Circuit 1 DRIVER DOOR AJAR SWITCH SENSE G75 20VT 2 GROUND Z917 20BK Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 15347 Connector: Name : LATCH-DOOR-DRIVER Color : BLACK # of pins : 4 Qualifier : (POWER LOCKS) Pin Description Circuit 1 DRIVER DOOR AJAR SWITCH SENSE G75 20VT 2 GROUND Z917 20BK 3 DOOR UNLOCK DRIVER LEFT FRONT P1 18TN/LG 4 DOOR LOCK DRIVER LEFT DOORS P393 18LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 15348 Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 15349 Power Door Lock Actuator: Diagrams Latch-Door-Left Rear Component ID: 190 Component : LATCH-DOOR-LEFT REAR Connector: Name : LATCH-DOOR-LEFT REAR Color : BLACK # of pins : 2 Qualifier : (BASE) Pin Description Circuit 1 LEFT REAR DOOR AJAR SWITCH SENSE G77 20VT/GY 2 GROUND Z917 20BK Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 15350 Connector: Name : LATCH-DOOR-LEFT REAR Color : BLACK # of pins : 4 Qualifier : (POWER LOCKS) Pin Description Circuit 1 LEFT REAR DOOR AJAR SWITCH SENSE G77 20VT/GY 2 GROUND Z917 20BK 3 DOOR UNLOCK DRIVER LEFT REAR P5 18TN/OR 4 DOOR LOCK DRIVER LEFT DOORS P393 18LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 15351 Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 15352 Power Door Lock Actuator: Diagrams Latch-Door-Passenger Component ID: 191 Component : LATCH-DOOR-PASSENGER Connector: Name : LATCH-DOOR-PASSENGER Color : BLACK # of pins : 2 Qualifier : (BASE) Pin Description Circuit 1 DRIVER DOOR AJAR SWITCH SENSE G74 20VT 2 GROUND Z917 20BK Component Location - 56 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 15353 Connector: Name : LATCH-DOOR-PASSENGER Color : BLACK # of pins : 4 Qualifier : (POWER LOCKS) Pin Description Circuit 1 PASSENGER DOOR AJAR SWITCH SENSE G74 20VT/WT 2 GROUND Z917 20BK 3 DOOR UNLOCK DRIVER RIGHT DOORS G778 18VT/LB 4 DOOR LOCK DRIVER RIGHT DOORS P392 18LG/DB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 15354 Component Location - 56 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 15355 Power Door Lock Actuator: Diagrams Latch-Door-Right Rear Component ID: 192 Component : LATCH-DOOR-RIGHT REAR Connector: Name : LATCH-DOOR-RIGHT REAR Color : BLACK # of pins : 2 Qualifier : (BASE) Pin Description Circuit 1 RIGHT REAR DOOR AJAR SWITCH SENSE G76 20VT/GY 2 GROUND Z917 20BK Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 15356 Connector: Name : LATCH-DOOR-RIGHT REAR Color : BLACK # of pins : 4 Qualifier : (POWER LOCKS) Pin Description Circuit 1 RIGHT REAR DOOR AJAR SWITCH SENSE G76 20VT/GY 2 GROUND Z917 20BK 3 DOOR UNLOCK DRIVER RIGHT DOORS G778 18TN/OR 4 DOOR LOCK DRIVER RIGHT DOORS P392 18LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Latch-Door-Driver > Page 15357 Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Description and Operation > Description Power Door Lock Actuator: Description and Operation Description DESCRIPTION The lock mechanisms are actuated by a reversible electric motor mounted within each door. The power lock motors are integral to the door latch units. The power lock motors cannot be adjusted or repaired and, if faulty or damaged, the door latch unit must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Description and Operation > Description > Page 15360 Power Door Lock Actuator: Description and Operation Operation OPERATION The door lock motors are controlled by the instrument cluster. A positive and negative battery connection to the two motor terminals will cause the motor to move in one direction. Reversing the current will cause the motor to move in the opposite direction. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Switch-Door Lock-Passenger Power Door Lock Switch: Locations Switch-Door Lock-Passenger Component ID: 462 Component : SWITCH-DOOR LOCK-PASSENGER Connector: Name : SWITCH-DOOR LOCK-PASSENGER Color : NATURAL # of pins : 6 Pin Description Circuit 1 PASSENGER DOOR LOCK SWITCH MUX G160 20VT/LG 2 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 3-4-5 GROUND Z917 20BK 6-Component Location - 56 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Switch-Door Lock-Passenger > Page 15365 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Switch-Door Lock-Passenger > Page 15366 Power Door Lock Switch: Locations Switch-Window/Door Lock-Driver Component ID: 494 Component : SWITCH-WINDOW/DOOR LOCK-DRIVER Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C1 Color : BLUE # of pins : 12 Pin Description Circuit 1 RIGHT REAR WINDOW DRIVER (DOWN) Q612 14OR/DB 2 RIGHT REAR WINDOW DRIVER (UP) Q412 14OR/LB 3 MASTER WINDOW SWITCH RIGHT FRONT (UP) Q16 12OR/TN 4 LEFT REAR WINDOW DRIVER (UP) Q411 14OR/WT 5 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 6 MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Q26 12OR/GY 7 DRIVER DOOR LOCK SWITCH MUX G161 20VT/DG 8 GROUND Z939 12BK 9 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 12PK/YL 10 LEFT REAR WINDOW DRIVER (DOWN) Q611 14OR/GY 11 GROUND Z939 18BK 12 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Switch-Door Lock-Passenger > Page 15367 Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C2 Color : BLUE # of pins : 8 Pin Description Circuit 1 LEFT MIRROR UP DRIVER P71 20TN/DG 2 LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) P195 18LG/YL 3 FUSED B(+) A940 18RD 4 RIGHT MIRROR LEFT DRIVER P74 18TN/OR 5 GROUND Z939 18BK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Switch-Door Lock-Passenger > Page 15368 6 LEFT MIRROR LEFT DRIVER P75 20TN/LG 7 RIGHT MIRROR UP DRIVER P72 18TN/GY 8 POWER WINDOW SWITCH FEED Q15 12OR/LB Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger Power Door Lock Switch: Diagrams Switch-Door Lock-Passenger Component ID: 462 Component : SWITCH-DOOR LOCK-PASSENGER Connector: Name : SWITCH-DOOR LOCK-PASSENGER Color : NATURAL # of pins : 6 Pin Description Circuit 1 PASSENGER DOOR LOCK SWITCH MUX G160 20VT/LG 2 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 3-4-5 GROUND Z917 20BK 6-Component Location - 56 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger > Page 15371 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger > Page 15372 Power Door Lock Switch: Diagrams Switch-Window/Door Lock-Driver Component ID: 494 Component : SWITCH-WINDOW/DOOR LOCK-DRIVER Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C1 Color : BLUE # of pins : 12 Pin Description Circuit 1 RIGHT REAR WINDOW DRIVER (DOWN) Q612 14OR/DB 2 RIGHT REAR WINDOW DRIVER (UP) Q412 14OR/LB 3 MASTER WINDOW SWITCH RIGHT FRONT (UP) Q16 12OR/TN 4 LEFT REAR WINDOW DRIVER (UP) Q411 14OR/WT 5 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 6 MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Q26 12OR/GY 7 DRIVER DOOR LOCK SWITCH MUX G161 20VT/DG 8 GROUND Z939 12BK 9 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 12PK/YL 10 LEFT REAR WINDOW DRIVER (DOWN) Q611 14OR/GY 11 GROUND Z939 18BK 12 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger > Page 15373 Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C2 Color : BLUE # of pins : 8 Pin Description Circuit 1 LEFT MIRROR UP DRIVER P71 20TN/DG 2 LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) P195 18LG/YL 3 FUSED B(+) A940 18RD 4 RIGHT MIRROR LEFT DRIVER P74 18TN/OR 5 GROUND Z939 18BK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger > Page 15374 6 LEFT MIRROR LEFT DRIVER P75 20TN/LG 7 RIGHT MIRROR UP DRIVER P72 18TN/GY 8 POWER WINDOW SWITCH FEED Q15 12OR/LB Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Description and Operation > Description Power Door Lock Switch: Description and Operation Description DESCRIPTION A window/lock switch is used on all models equipped with power locks, power windows, and power mirrors. The window/lock switch houses the following switches: - Power Lock Switch - A two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Mirror Selector Switch - A three-position rocker switch selects the right or left power mirror for adjustment, or turns the power mirror system Off. - Power Mirror Adjustment Switches - Four momentary, arrowhead shaped, directional switches allow the driver to adjust the selected power mirror in the Up, Down, Right, or Left directions. - Power Window Lockout Switch - A two-way, latching, push-button switch allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches. - Power Window Switches - A two-way, momentary power window switch for the driver side front door. This switch also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, there are individual master switches for each passenger door power window. The window/lock switch also incorporates several green Light-Emitting Diodes (LEDs) that illuminate the power lock and power window switch paddles, and the power mirror switch directional buttons to improve switch visibility. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Description and Operation > Description > Page 15377 Power Door Lock Switch: Description and Operation Operation OPERATION The window/lock switch combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single unit. Power Lock Switch The power lock switch circuitry is connected in series between ground and the driver door switch mux input of the instrument cluster. Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the instrument cluster input, which allows the instrument cluster to sense the switch position. Based upon the power lock switch input, the instrument cluster controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door latches. The Light-Emitting Diode (LED) in the power lock switch is connected to battery current through the power window circuit breaker in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run-acc) circuit. The switch will be illuminated whenever the ignition switch is in the On or Accessory positions. Power Window Switches The power window switch circuitry is connected to battery current through a circuit breaker in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run-acc) circuit so that the power windows will operate whenever the ignition switch is in the On or Accessory positions. Each two-way, momentary master passenger power window switch provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The switch for the driver side front door power window is labeled "Auto" and includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the master switches. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Power Mirror Switches The power mirror switch circuitry is connected to battery current through a fuse in the TIPM on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one to select the left mirror, and a neutral Off position. After the right or left mirror is selected, one of four directional buttons is depressed to move the selected mirror Up, Down, Right or Left. The power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the power mirror switch is connected to battery current through the power window circuit breaker in the TIPM on a fused ignition switch output (run-acc) circuit so that the switch directional buttons will be illuminated whenever the ignition switch is in the On or Accessory positions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Power Lock Switch Power Door Lock Switch: Testing and Inspection Power Lock Switch POWER LOCK SWITCH The Light-Emitting Diode (LED) illumination lamp of the power lock switch receives battery current through a fuse in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run) circuit. The power lock switch on the driver side front door trim panel is integral to the window/lock switch. If the power lock switch operates, but the LED is inoperative, check for battery current at the switch with the ignition switch in the On position. If OK, replace the faulty switch. Refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. Remove the power lock switch from the door trim panel. Disconnect the door wire harness connector for the power lock switch from the switch connector receptacle. 2. Test the power lock switch resistance. See the Power Lock Switch Test chart to determine if the resistance is correct for the switch in each switch position. If not OK, replace the faulty power lock switch as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Power Lock Switch > Page 15380 Power Door Lock Switch: Testing and Inspection Window/Lock Switch WINDOW/LOCK SWITCH The Light-Emitting Diode (LED) illumination lamps for all of the Driver Door Module (DDM) power window, power lock, and power mirror switches receive battery current through the power window circuit breaker in the Totally Integrated Power Module (TIPM). If all of the LED's are inoperative in the DDM, be certain to diagnose the power window system before replacing the switch unit. If only one LED in the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty DDM. Refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles. 2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position. If not OK, replace the faulty DDM as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Power Lock Switch > Page 15381 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Power Lock Switch > Page 15382 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Removal Power Door Lock Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Removal > Page 15385 Power Door Lock Switch: Service and Repair Installation INSTALLATION 1. Install switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions Memory Positioning Systems: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15391 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15392 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15393 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15394 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15395 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15396 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15397 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15398 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15399 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15400 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15401 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15402 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15403 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15404 Memory Positioning Systems: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15405 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15406 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15407 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15408 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and Repair Power Mirror Switch: Service and Repair REMOVAL The power mirror switch is included with the window/lock switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 23-046-07 > Oct > 07 > Body - Horizontal Paint Surface Etching Paint: Customer Interest Body - Horizontal Paint Surface Etching NUMBER: 23-046-07 GROUP: Body DATE: October 30, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-003-06, DATED JANUARY 19, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL YEARS AND MODELS. SUBJECT: Paint Repair - Etching OVERVIEW: This bulletin involves evaluating the paint condition on all horizontal panels for etching and using the procedures listed in the Paint Condition Deck p/n 81-316-0507 or using the information listed in this bulletin MODELS: 2006 - (CS) Pacifica **2008** 2006 - (DR/D1/DC/DH) Ram Truck **2008** 2006 - (HB) Durango **2008** **2007 - 2008 (HG) Aspen** 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan **2007 - 2008 (JS) Sebring/Sebring Convertible/Avenger** **2007 - 2008 (JK) Wrangler** **2007 - 2008 (KA) Nitro** 2006- (KJ) Liberty **2007** **2008 (KK) Liberty 2006 - (LX) 300/Magnum/**Charger** **2008** **2007 - 2008 (MK) Compass/Patriot** 2006- (ND) Dakota **2008** **2007 - 2008 (PM) Caliber** 2006 - (RS) Town & Country/Caravan **2007** **2008 (RI) Town & Country/Grand Caravan** 2006 (TJ) Wrangler 2005 - (WK) Grand Cherokee **2008** 2006 - (XK) Commander Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 23-046-07 > Oct > 07 > Body - Horizontal Paint Surface Etching > Page 15421 **2008** DIAGNOSIS: Inspect the vehicle horizontal panels for the appearance of an etched surface (picture available in "PAINT CONDITION DECK" - publication number 81-316-0507 - see "INSECT ETCH" graphic). Two procedures are available depending on the severity of the condition. Repair Procedure "A" is for conditions that do not show through to primer and Repair Procedure "B" is for conditions that show primer within the etch area. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE "A" FINESSE: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. Measure and record paint film thickness in areas to be sanded using an electronic mil gauge (PSE). 5. Use 2000 grit sand paper mounted to a ridged backer to remove all etching. 6. If you remove more than 0.5 mil of clear coat you will need to refinish using repair procedure "B" refinish. 7. If refinishing is not required polish sanded areas using Mopar Compound Power Cleaner # BSMM8432. 8. Remove swirl marks using Mopar Swirl Free polish # BSMM8232. 9. Detail vehicle as required. REPAIR PROCEDURE "B" REFINISH: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. DA surface with 600 grit sand paper. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 23-046-07 > Oct > 07 > Body - Horizontal Paint Surface Etching > Page 15422 5. Clean with appropriate solvent per paint supplier recommendations. 6. Feather edge the damaged areas. 7. Apply corrosion resistant primer to bare metal spots if they exist. 8. Spot prime with primer surfacer. 9. Block sand the primer surfacer. 10. Final sand per paint suppliers recommendations. 11. Clean with appropriate solvent. 12. Tack off the repair area. 13. Apply basecoat with appropriate hardener per paint supplier recommendations. 14. Allow flash time per paint suppliers recommendations and tack off area. 15. Apply clear coat per paint suppliers recommendations. 16. Detail vehicle as required. NOTE: No clear coat spot Repair should be performed on class "A" surfaces. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 23-046-07 > Oct > 07 > Body - Horizontal Paint Surface Etching > Page 15423 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 23-046-07 > Oct > 07 > Body - Horizontal Paint Surface Etching Paint: All Technical Service Bulletins Body - Horizontal Paint Surface Etching NUMBER: 23-046-07 GROUP: Body DATE: October 30, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-003-06, DATED JANUARY 19, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL YEARS AND MODELS. SUBJECT: Paint Repair - Etching OVERVIEW: This bulletin involves evaluating the paint condition on all horizontal panels for etching and using the procedures listed in the Paint Condition Deck p/n 81-316-0507 or using the information listed in this bulletin MODELS: 2006 - (CS) Pacifica **2008** 2006 - (DR/D1/DC/DH) Ram Truck **2008** 2006 - (HB) Durango **2008** **2007 - 2008 (HG) Aspen** 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan **2007 - 2008 (JS) Sebring/Sebring Convertible/Avenger** **2007 - 2008 (JK) Wrangler** **2007 - 2008 (KA) Nitro** 2006- (KJ) Liberty **2007** **2008 (KK) Liberty 2006 - (LX) 300/Magnum/**Charger** **2008** **2007 - 2008 (MK) Compass/Patriot** 2006- (ND) Dakota **2008** **2007 - 2008 (PM) Caliber** 2006 - (RS) Town & Country/Caravan **2007** **2008 (RI) Town & Country/Grand Caravan** 2006 (TJ) Wrangler 2005 - (WK) Grand Cherokee **2008** 2006 - (XK) Commander Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 23-046-07 > Oct > 07 > Body - Horizontal Paint Surface Etching > Page 15429 **2008** DIAGNOSIS: Inspect the vehicle horizontal panels for the appearance of an etched surface (picture available in "PAINT CONDITION DECK" - publication number 81-316-0507 - see "INSECT ETCH" graphic). Two procedures are available depending on the severity of the condition. Repair Procedure "A" is for conditions that do not show through to primer and Repair Procedure "B" is for conditions that show primer within the etch area. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE "A" FINESSE: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. Measure and record paint film thickness in areas to be sanded using an electronic mil gauge (PSE). 5. Use 2000 grit sand paper mounted to a ridged backer to remove all etching. 6. If you remove more than 0.5 mil of clear coat you will need to refinish using repair procedure "B" refinish. 7. If refinishing is not required polish sanded areas using Mopar Compound Power Cleaner # BSMM8432. 8. Remove swirl marks using Mopar Swirl Free polish # BSMM8232. 9. Detail vehicle as required. REPAIR PROCEDURE "B" REFINISH: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. DA surface with 600 grit sand paper. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 23-046-07 > Oct > 07 > Body - Horizontal Paint Surface Etching > Page 15430 5. Clean with appropriate solvent per paint supplier recommendations. 6. Feather edge the damaged areas. 7. Apply corrosion resistant primer to bare metal spots if they exist. 8. Spot prime with primer surfacer. 9. Block sand the primer surfacer. 10. Final sand per paint suppliers recommendations. 11. Clean with appropriate solvent. 12. Tack off the repair area. 13. Apply basecoat with appropriate hardener per paint supplier recommendations. 14. Allow flash time per paint suppliers recommendations and tack off area. 15. Apply clear coat per paint suppliers recommendations. 16. Detail vehicle as required. NOTE: No clear coat spot Repair should be performed on class "A" surfaces. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 23-046-07 > Oct > 07 > Body - Horizontal Paint Surface Etching > Page 15431 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 15432 Paint: By Symptom Technical Service Bulletin # 23-046-07 Date: 071030 Body - Horizontal Paint Surface Etching NUMBER: 23-046-07 GROUP: Body DATE: October 30, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-003-06, DATED JANUARY 19, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL YEARS AND MODELS. SUBJECT: Paint Repair - Etching OVERVIEW: This bulletin involves evaluating the paint condition on all horizontal panels for etching and using the procedures listed in the Paint Condition Deck p/n 81-316-0507 or using the information listed in this bulletin MODELS: 2006 - (CS) Pacifica **2008** 2006 - (DR/D1/DC/DH) Ram Truck **2008** 2006 - (HB) Durango **2008** **2007 - 2008 (HG) Aspen** 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan **2007 - 2008 (JS) Sebring/Sebring Convertible/Avenger** **2007 - 2008 (JK) Wrangler** **2007 - 2008 (KA) Nitro** 2006- (KJ) Liberty **2007** **2008 (KK) Liberty 2006 - (LX) 300/Magnum/**Charger** **2008** **2007 - 2008 (MK) Compass/Patriot** 2006- (ND) Dakota **2008** **2007 - 2008 (PM) Caliber** 2006 - (RS) Town & Country/Caravan **2007** **2008 (RI) Town & Country/Grand Caravan** 2006 (TJ) Wrangler 2005 - (WK) Grand Cherokee Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 15433 **2008** 2006 - (XK) Commander **2008** DIAGNOSIS: Inspect the vehicle horizontal panels for the appearance of an etched surface (picture available in "PAINT CONDITION DECK" - publication number 81-316-0507 - see "INSECT ETCH" graphic). Two procedures are available depending on the severity of the condition. Repair Procedure "A" is for conditions that do not show through to primer and Repair Procedure "B" is for conditions that show primer within the etch area. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE "A" FINESSE: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. Measure and record paint film thickness in areas to be sanded using an electronic mil gauge (PSE). 5. Use 2000 grit sand paper mounted to a ridged backer to remove all etching. 6. If you remove more than 0.5 mil of clear coat you will need to refinish using repair procedure "B" refinish. 7. If refinishing is not required polish sanded areas using Mopar Compound Power Cleaner # BSMM8432. 8. Remove swirl marks using Mopar Swirl Free polish # BSMM8232. 9. Detail vehicle as required. REPAIR PROCEDURE "B" REFINISH: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 15434 4. DA surface with 600 grit sand paper. 5. Clean with appropriate solvent per paint supplier recommendations. 6. Feather edge the damaged areas. 7. Apply corrosion resistant primer to bare metal spots if they exist. 8. Spot prime with primer surfacer. 9. Block sand the primer surfacer. 10. Final sand per paint suppliers recommendations. 11. Clean with appropriate solvent. 12. Tack off the repair area. 13. Apply basecoat with appropriate hardener per paint supplier recommendations. 14. Allow flash time per paint suppliers recommendations and tack off area. 15. Apply clear coat per paint suppliers recommendations. 16. Detail vehicle as required. NOTE: No clear coat spot Repair should be performed on class "A" surfaces. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 15435 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-046-07 Date: 071030 Body - Horizontal Paint Surface Etching NUMBER: 23-046-07 GROUP: Body DATE: October 30, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-003-06, DATED JANUARY 19, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL YEARS AND MODELS. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 15436 SUBJECT: Paint Repair - Etching OVERVIEW: This bulletin involves evaluating the paint condition on all horizontal panels for etching and using the procedures listed in the Paint Condition Deck p/n 81-316-0507 or using the information listed in this bulletin MODELS: 2006 - (CS) Pacifica **2008** 2006 - (DR/D1/DC/DH) Ram Truck **2008** 2006 - (HB) Durango **2008** **2007 - 2008 (HG) Aspen** 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan **2007 - 2008 (JS) Sebring/Sebring Convertible/Avenger** **2007 - 2008 (JK) Wrangler** **2007 - 2008 (KA) Nitro** 2006- (KJ) Liberty **2007** **2008 (KK) Liberty 2006 - (LX) 300/Magnum/**Charger** **2008** **2007 - 2008 (MK) Compass/Patriot** 2006- (ND) Dakota **2008** **2007 - 2008 (PM) Caliber** 2006 - (RS) Town & Country/Caravan **2007** **2008 (RI) Town & Country/Grand Caravan** 2006 (TJ) Wrangler 2005 - (WK) Grand Cherokee **2008** 2006 - (XK) Commander **2008** DIAGNOSIS: Inspect the vehicle horizontal panels for the appearance of an etched surface (picture available in "PAINT CONDITION DECK" - publication number 81-316-0507 - see "INSECT ETCH" graphic). Two procedures are available depending on the severity of the condition. Repair Procedure "A" is for conditions that do not show through to primer and Repair Procedure "B" is for conditions that show primer within the etch area. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 15437 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE "A" FINESSE: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. Measure and record paint film thickness in areas to be sanded using an electronic mil gauge (PSE). 5. Use 2000 grit sand paper mounted to a ridged backer to remove all etching. 6. If you remove more than 0.5 mil of clear coat you will need to refinish using repair procedure "B" refinish. 7. If refinishing is not required polish sanded areas using Mopar Compound Power Cleaner # BSMM8432. 8. Remove swirl marks using Mopar Swirl Free polish # BSMM8232. 9. Detail vehicle as required. REPAIR PROCEDURE "B" REFINISH: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. DA surface with 600 grit sand paper. 5. Clean with appropriate solvent per paint supplier recommendations. 6. Feather edge the damaged areas. 7. Apply corrosion resistant primer to bare metal spots if they exist. 8. Spot prime with primer surfacer. 9. Block sand the primer surfacer. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 15438 10. Final sand per paint suppliers recommendations. 11. Clean with appropriate solvent. 12. Tack off the repair area. 13. Apply basecoat with appropriate hardener per paint supplier recommendations. 14. Allow flash time per paint suppliers recommendations and tack off area. 15. Apply clear coat per paint suppliers recommendations. 16. Detail vehicle as required. NOTE: No clear coat spot Repair should be performed on class "A" surfaces. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 15439 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes Paint: Application and ID Paint Codes PAINT CODES Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 15442 Paint: Application and ID Paint Code Location PAINT CODE LOCATION (TYPICAL-ALL MODELS) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Description and Operation > Basecoat/Clearcoat Finish - Description Paint: Description and Operation Basecoat/Clearcoat Finish - Description DESCRIPTION The original equipment paint finish is a multi step process that involves cleaning, applying electro de-position (E-coat), anti-chip primer, basecoat, and clearcoat steps. CAUTION: Do not use abrasive chemicals, abrasive compounds or harsh alkaline based cleaning solvents on the painted surfaces of a vehicle. Failure to follow this caution can result in damage to vehicle finish. On most vehicles a two-part paint application (basecoat/clearcoat) is used. Color paint that is applied to primer is called basecoat. A clear coat paint is then applied to protect the basecoat from ultraviolet light and to provide a durable high-gloss finish. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Description and Operation > Basecoat/Clearcoat Finish - Description > Page 15445 Paint: Description and Operation Paint Code - Description DESCRIPTION Exterior vehicle body color(s) are identified on the Vehicle Certification Label or the Body Code Plate. The first digit of the paint code listed on the vehicle indicates the sequence of application, i.e.: P = primary coat, Q = secondary coat. The color names provided in the Paint and Trim Code Description chart are the same color names used on most repair product containers. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Description and Operation > Basecoat/Clearcoat Finish - Description > Page 15446 Paint: Description and Operation Paint Touch-up - Description DESCRIPTION If the painted metal surface of a vehicle becomes scratched or chipped, it should be touched-up as soon as possible to avoid corrosion. WARNING: Use an OSHA approved respirator and safety glasses when spraying paint or solvents in a confined area. Failure to follow this warning may result in possible personal injury or death. When repairing painted metal surfaces, for best results, use MOPAR(R) Scratch Filler/Primer, Touch-Up Paints and Clear Top Coat. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up Paint: Service and Repair Paint Touch-Up PAINT TOUCH-UP 1. Scrape any loose paint and corrosion from inside the scratch or chip. WARNING: Avoid prolonged skin contact with petroleum or alcohol-based cleaning solvents. Failure to follow this warning can result in possible personal injury or death. 2. Clean affected area with MOPAR(R) Tar/Road Oil Remover or equivalent, and allow to dry. 3. Fill the inside of the scratch or chip with a coat of filler/primer. Do not overlap primer onto good surface finish. The applicator brush should be wet enough to puddle-fill the scratch or chip without running. Do not stroke brush applicator on body surface. Allow the filler/primer to dry hard. 4. Cover the filler/primer with color touch-up paint. Do not overlap touch-up color onto the original color coat around the scratch or chip. Butt the new color to the original color, if possible. Do not stroke applicator brush on body surface. Allow touch-up paint to dry hard. 5. On vehicles without clearcoat, the touch-up color can be lightly finesse sanded (1500 grit) and polished with rubbing compound. 6. On vehicles with clearcoat, apply clear top coat to touch-up paint with the same technique as described in STEP 4. Allow clear top coat to dry hard. If desired, the clearcoat can be lightly finesse sanded (1500 grit) and polished with rubbing compound. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up > Page 15449 Paint: Service and Repair Finesse Sanding, Buffing, And Polishing - Description DESCRIPTION CAUTION: Do not remove more than 0.5 mils of clearcoat finish when sanding, hand buffing or polishing. Basecoat paint must retain clearcoat for durability. CAUTION: If the finish has been finesse sanded in the past, it cannot be repeated. Failure to follow this caution can result in damage to vehicle finish. NOTE: Finesse sanding should only be performed by a trained automotive paint technician. Minor acid etching, orange peel, or smudging in a clearcoat or single-stage finish can be reduced with light finesse sanding, hand buffing and polishing. Use a Paint Thickness Gauge #PR-ETG-2X or equivalent to determine clearcoat or single-stage paint thickness before and after the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair > Radiator Upper Crossmember - Installation Radiator Support: Service and Repair Radiator Upper Crossmember - Installation INSTALLATION 1. Position and align the upper radiator crossmember (2) to the fender rails. 2. Install the four bolts (1 and 3) that secure the upper radiator crossmember to the fender rails. Tighten the bolts to 28 Nm (21 ft. lbs.). 3. Install the bolts (1 and 2) that secure the A/C condenser and the radiator to the upper radiator crossmember (3). Tighten the bolts to 8 Nm (75 in. lbs.). 4. Install the hood latch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair > Radiator Upper Crossmember - Installation > Page 15454 Radiator Support: Service and Repair Radiator Upper Crossmember - Removal REMOVAL 1. Remove the hood latch from the upper radiator crossmember (3) and position the latch out of the way. 2. Remove the bolts (1 and 2) that secure the A/C condenser and the radiator to the upper radiator crossmember. 3. Remove the four bolts (1 and 3) that secure the upper radiator crossmember (2) to the fender rails and remove the crossmember. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Component ID: 211 Component : MODULE-SENTRY KEY REMOTE ENTRY Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z109 20BK/GY 5 FUSED B(+) A114 18GY/RD 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT 8-Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 15459 Component Location - 41 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 15460 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 15461 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 15462 Keyless Entry Module: Diagrams Component ID: 211 Component : MODULE-SENTRY KEY REMOTE ENTRY Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY Color : BLACK # of pins : 8 Pin Description Circuit 1 IGNITION SWITCH SENSE G20 20VT/BR 2-3 FUSED IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT 4 GROUND Z109 20BK/GY 5 FUSED B(+) A114 18GY/RD 6 CAN B BUS (+) D55 20WT/OR 7 CAN B BUS (-) D54 20WT 8-Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 15463 Component Location - 41 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 15464 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 15465 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry Keyless Entry Module: Description and Operation Module-Remote Keyless Entry Description DESCRIPTION When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 Km/h(15 mph) will also cancel the panic event. Operation OPERATION Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 15468 Keyless Entry Module: Description and Operation Sentry Key Remote Entry Module Description DESCRIPTION The Sentry Key REmote Entry Module (SKREEM) (1) is sometimes referred to as the Wireless Control Module (WCM). The SKREEM is the primary component of the Sentry Key Immobilizer System (SKIS). It is also the receiver for the Remote Keyless Entry (RKE) system. The SKREEM is located on the right side of the steering column, near the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM has an integral molded plastic halo-like antenna ring (4) that extends from the bottom. When the SKREEM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle (3) is located just behind the antenna ring on the bottom of the SKREEM housing. An integral molded plastic mounting tab (2) on the rear corner of the SKREEM housing has a hole in the center through which a screw passes to secure the unit to the steering column. The SKREEM is connected to the vehicle electrical system through a single take out and connector of the instrument panel wire harness. Two SKREEM modules are used: one for vehicles equipped with RKE only, and one for vehicles equipped with RKE and SKIS. The SKREEM cannot be adjusted or repaired. If ineffective or damaged, the entire SKREEM unit must be replaced. Operation OPERATION The Sentry Key REmote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver. The SKREEM communicates over the Controller Area Network (CAN) data bus with the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), the Powertrain Control Module (PCM)/Engine Control Module (ECM) or the diagnostic scan tool. The SKREEM and the PCM/ECM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS) disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKREEM or the PCM/ECM. However, the use of this strategy also means that replacement of either the SKREEM or the PCM/ECM units will require a system initialization procedure to restore system operation. The SKREEM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM. For added system security, each SKREEM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM or ECM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM. Therefore, the Secret Key code is a common element that is found in every component of the SKIS. Another security code called a PIN, is used to gain access to the SKREEM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKREEM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM or ECM during SKIS initialization. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 15469 In the event that a SKREEM replacement is required, the Secret Key code can be transferred to the new SKREEM from the PCM or ECM using a diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the ON position, the SKREEM transmits an RF signal to excite the transponder in the ignition key. The SKREEM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM sends an electronic valid key message to the PCM/ECM over the CAN bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the SKREEM sends an invalid key message to the PCM/ECM. The PCM/ECM will enable or disable engine operation based upon the status of the SKREEM messages. It is important to note that the default condition in the PCM or ECM is an invalid key; therefore, if no message is received from the SKREEM by the PCM or ECM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM also sends security indicator request messages to the EMIC over the CAN data bus to tell the EMIC how to operate the security indicator. The security indicator request message from the SKREEM tells the EMIC to turn the indicator ON for about three seconds each time the ignition switch is turned to the ON position as a bulb test. After completion of the bulb test, the SKREEM sends security indicator request messages to the EMIC to turn the indicator OFF, turn the indicator ON, or to flash the indicator ON and OFF. If the security indicator flashes or stays ON solid after the bulb test, it signifies a SKIS fault. If the SKREEM detects a system malfunction or the SKIS has become ineffective, the security indicator will stay ON solid. If the SKREEM detects an invalid key or if a key transponder-related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM will also send messages to the EMIC to flash the security indicator whenever the Customer Learn programming mode is being utilized. The SKIS performs a self-test each time the ignition switch is turned to the ON position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM memory if a system malfunction is detected. The hard wired circuits of the SKREEM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SKREEM or the electronic controls or communication between other modules and devices that provide some features of the SKIS. The most reliable, efficient, and accurate means to diagnose the SKREEM or the electronic controls and communication related to SKREEM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Page 15470 Keyless Entry Module: Testing and Inspection REMOTE KEYLESS ENTRY MODULE The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Removal Keyless Entry Module: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, push inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 15473 8. Disconnect the wire harness connector (2) from the Sentry Key REmote Entry Module (SKREEM) (1). 9. Remove the screw (3) that secures the SKREEM (1) to the steering column (2). 10. Disengage the antenna ring from around the ignition lock cylinder housing and remove the SKREEM. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 15474 Keyless Entry Module: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the Sentry Key REmote Entry Module (SKREEM) (1) onto the steering column (2) with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw (3) that secures the SKREEM to the steering column housing. Tighten the screw to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the SKREEM (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Removal > Page 15475 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). 10. Reconnect the battery negative cable. NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS) if the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Description Seat Heater Control Module: Description and Operation Description DESCRIPTION Momentary contact push button switch/modules mounted in the instrument panel center bezel operate the heated seat system. Each heated seat switch/module has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected level (Low or High) of the seat heater. Pressing the switch/module button initiates heat. Heat remains on until switched off or until the ignition is turned off. If switched off by the ignition, a switch/module button must be pressed to restart heating. The switch/modules contain the solid state electronic control and diagnostic logic circuitry for the heated seat system. If any of the heated seat elements are inoperative or damaged one or more of the LED lamps in the switch/module for the effected seat will flash. The LED indicator lamps in each heated seat switch/module cannot be repaired. If the LED lamps are faulty or damaged, or the switch/module is inoperative or damaged the individual heated seat switch/module assembly must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Description > Page 15480 Seat Heater Control Module: Description and Operation Operation OPERATION A Heated Seat Switch/Module is used to control the heated seat system. The heated seat switch/modules receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The switch/module responds to heated seat switch/module button input and ignition switch status inputs by controlling the 12v output to the front seat heating elements through integral solid-state relays. When either of the heated seat switch/module buttons are depressed the heating element for the selected seat is energized. Amber Light Emitting Diodes (LEDS) on the side of each switch/module indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. Pressing the switch/module button once will select high-level heating. Pressing the button a second time will select low-level heating. Pressing the button a third time will shut the heating elements off. The heated seat switch/module energizes an integral solid-state relay, which supplies battery current to the heating elements. When high-temperature heating is selected, the heaters provide a boosted heat level during the first four minutes of operation after heating is activated. The heat output then drops to the normal high-temperature level. If high-level heating is selected, the control system will automatically switch to the low level after two hours of continuous operation. At that time, the number of illuminated LEDs changes from two to one, indicating the change. Operation on the low setting will continue indefinitely until the switch/module button is pushed to turn the system off. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Removal Seat Heater Control Module: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. 3. Disconnect the switch/module electrical connectors. 4. Using an appropriate flat bladed tool, remove the heated seat switch/module from the bezel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Removal > Page 15483 Seat Heater Control Module: Service and Repair Installation INSTALLATION 1. Align the tabs of the switch/module to the instrument panel center bezel and gently push together until the tabs are securely in place. 2. Connect the switch/module electrical connectors. 3. Install the instrument panel center bezel. 4. Connect the battery negative cable. 5. Verify heated seat system operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Removal Sun Shade: Service and Repair Removal REMOVAL 1. Remove the drain channel. 2. Push up the front center of the sunshade (1) to pop out the front two feet. 3. Rotate the sunshade (2) so that the other feet (1) are removed from the guide track. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Removal > Page 15490 Sun Shade: Service and Repair Installation INSTALLATION 1. Verify the sunshade track is free of obstructions like the trim lace/ring. 2. Start with sunshade (2) at an angle with one foot (1) in the track. 3. Rotate the sunshade so the other rear foot is in the track as well as the 2 other feet (3) on the same side as the first foot. 4. To insert the remaining two feet (2) apply force to the middle front of sunshade (3) and guide them into the track. 5. Check that all the feet are in the right track and verify sunshade operation. 6. Install the drain channel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof Sunroof / Moonroof Cable: Customer Interest Body - Ratcheting Noise When Operating Sunroof NUMBER: 23-004-08 GROUP: Body DATE: January 16, 2008 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 23-045-06 DATED OCTOBER 14, 2006 AND 23-51-06 DATED NOVEMBER 4, 2006. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF WH/XH/L2 MODELS AND 2008 MODEL YEAR VEHICLES. SUBJECT: Ratcheting Sound During Sunroof Operation OVERVIEW: This bulletin involves replacing the sunroof drive cable conduit. MODELS: 2004 - **2008** (DR) Ram Truck **2007 (L2) 300C (China)** 2005 - **2008** (LE) 300C/300C Touring (International Markets) 2005 - 2008 (LX) 300/Charger/Magnum **2005 - 2008 (WH) Grand Cherokee (International Markets)** 2005 - **2008** (WK) Grand Cherokee **2006 - 2008 (XH) Commander (International Markets)** 2006 - 2008 (XK) Commander NOTE: This bulletin applies to DR/L2/LE/LX/WH/WK models with a Power Sunroof (sales code GWA) built before October 31, 2007 (MDH1031XX) and XH models with a Power Sunroof (sales code GWF) built before December 19, 2007 (MDH1219XX) and XK models with a Power Sunroof (sales code GWF) built before November 07, 2007 (MDH1107XX). SYMPTOM/CONDITION: A ratcheting sound is heard from sunroof module as the glass approaches the full open position. DIAGNOSIS: Lower the headliner to view the rear of the sunroof module assembly. Inspect the cable conduit tube(s) located at the rear corners of the sunroof module assembly for a kinked condition. Kinked condition most frequently occurs at passenger rear corner. If a kinked conduit is discovered, perform the appropriate Repair Procedure based on the vehicle below. PARTS REQUIRED: REPAIR PROCEDURE - DRIL2/LE/LX/WH/WK: 1. Ensure the sunroof module is in the full closed position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 15499 2. Remove M6 mounting bolts (4) at rear portion of sunroof module. 3. Remove the kinked cable conduit(s) from sunroof module retaining features starting from the end at the metal clip and work back to motor area, see (Fig 1). 4. Assemble new cable conduit, p/n 68003812AA, in reverse order of Step # 3) by inserting the flared end over the exposed end of the drive cable. Insure the flared end is sitting in the notch on the rear bulk head of sunroof module, (Fig 2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 15500 5. Snap the cable conduit into the retaining features in the rear bulk head (5 places) with the end of the tube retained in spring clip on the aluminum guide. Ensure the clip is within the provided scribe lines on aluminum guide, (Fig 3). 6. Torque the mounting bolts to 9 Nm (80 in. lbs.). 7. Operate Sunroof module. 8. Install headliner. REPAIR PROCEDURE - XH/XK: 1. Put the sunroof in the closed or vent position. 2. Drop headliner right front corner, by removing the right side A-pillar trim, B-pillar trim sun visor, sun visor clip and rear view mirror. 3. Look at and/or feel the drive cable conduit in the radius above the drain hose this is where the conduit will be kinked. 4. Remove 2 sunroof mounting fasteners, (Fig 4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 15501 5. Remove conduit from clip at side of sunroof module, (Fig 5). 6. Push the conduit up and inboard to release it from the retention feature on the front beam, (Fig 6) item 4. 7. Push the conduit up to release it from the additional retention features, (Fig. 6) item 2. 8. Pull the conduit out from over/off the drive cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 15502 9. Slide the new conduit, p/n 68003816AA, back over the drive cable. See (Fig. 6) item 1, to ensure conduit is seated into notch to the rear of the steel drive cable tube. 10. Secure the conduit in the retention features shown in (Fig. 6). 11. Install the conduit in the side clip. 12. Operate the sunroof to ensure the ratcheting noise is eliminated. 13. Install the mounting bolts. 14. Install the headliner, A-pillar trim, sun visor and visor clip. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof Sunroof / Moonroof Cable: All Technical Service Bulletins Body - Ratcheting Noise When Operating Sunroof NUMBER: 23-004-08 GROUP: Body DATE: January 16, 2008 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 23-045-06 DATED OCTOBER 14, 2006 AND 23-51-06 DATED NOVEMBER 4, 2006. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF WH/XH/L2 MODELS AND 2008 MODEL YEAR VEHICLES. SUBJECT: Ratcheting Sound During Sunroof Operation OVERVIEW: This bulletin involves replacing the sunroof drive cable conduit. MODELS: 2004 - **2008** (DR) Ram Truck **2007 (L2) 300C (China)** 2005 - **2008** (LE) 300C/300C Touring (International Markets) 2005 - 2008 (LX) 300/Charger/Magnum **2005 - 2008 (WH) Grand Cherokee (International Markets)** 2005 - **2008** (WK) Grand Cherokee **2006 - 2008 (XH) Commander (International Markets)** 2006 - 2008 (XK) Commander NOTE: This bulletin applies to DR/L2/LE/LX/WH/WK models with a Power Sunroof (sales code GWA) built before October 31, 2007 (MDH1031XX) and XH models with a Power Sunroof (sales code GWF) built before December 19, 2007 (MDH1219XX) and XK models with a Power Sunroof (sales code GWF) built before November 07, 2007 (MDH1107XX). SYMPTOM/CONDITION: A ratcheting sound is heard from sunroof module as the glass approaches the full open position. DIAGNOSIS: Lower the headliner to view the rear of the sunroof module assembly. Inspect the cable conduit tube(s) located at the rear corners of the sunroof module assembly for a kinked condition. Kinked condition most frequently occurs at passenger rear corner. If a kinked conduit is discovered, perform the appropriate Repair Procedure based on the vehicle below. PARTS REQUIRED: REPAIR PROCEDURE - DRIL2/LE/LX/WH/WK: 1. Ensure the sunroof module is in the full closed position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 15508 2. Remove M6 mounting bolts (4) at rear portion of sunroof module. 3. Remove the kinked cable conduit(s) from sunroof module retaining features starting from the end at the metal clip and work back to motor area, see (Fig 1). 4. Assemble new cable conduit, p/n 68003812AA, in reverse order of Step # 3) by inserting the flared end over the exposed end of the drive cable. Insure the flared end is sitting in the notch on the rear bulk head of sunroof module, (Fig 2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 15509 5. Snap the cable conduit into the retaining features in the rear bulk head (5 places) with the end of the tube retained in spring clip on the aluminum guide. Ensure the clip is within the provided scribe lines on aluminum guide, (Fig 3). 6. Torque the mounting bolts to 9 Nm (80 in. lbs.). 7. Operate Sunroof module. 8. Install headliner. REPAIR PROCEDURE - XH/XK: 1. Put the sunroof in the closed or vent position. 2. Drop headliner right front corner, by removing the right side A-pillar trim, B-pillar trim sun visor, sun visor clip and rear view mirror. 3. Look at and/or feel the drive cable conduit in the radius above the drain hose this is where the conduit will be kinked. 4. Remove 2 sunroof mounting fasteners, (Fig 4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 15510 5. Remove conduit from clip at side of sunroof module, (Fig 5). 6. Push the conduit up and inboard to release it from the retention feature on the front beam, (Fig 6) item 4. 7. Push the conduit up to release it from the additional retention features, (Fig. 6) item 2. 8. Pull the conduit out from over/off the drive cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 15511 9. Slide the new conduit, p/n 68003816AA, back over the drive cable. See (Fig. 6) item 1, to ensure conduit is seated into notch to the rear of the steel drive cable tube. 10. Secure the conduit in the retention features shown in (Fig. 6). 11. Install the conduit in the side clip. 12. Operate the sunroof to ensure the ratcheting noise is eliminated. 13. Install the mounting bolts. 14. Install the headliner, A-pillar trim, sun visor and visor clip. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > Customer Interest: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof Sunroof / Moonroof Cable Housing: Customer Interest Body - Ratcheting Noise When Operating Sunroof NUMBER: 23-004-08 GROUP: Body DATE: January 16, 2008 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 23-045-06 DATED OCTOBER 14, 2006 AND 23-51-06 DATED NOVEMBER 4, 2006. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF WH/XH/L2 MODELS AND 2008 MODEL YEAR VEHICLES. SUBJECT: Ratcheting Sound During Sunroof Operation OVERVIEW: This bulletin involves replacing the sunroof drive cable conduit. MODELS: 2004 - **2008** (DR) Ram Truck **2007 (L2) 300C (China)** 2005 - **2008** (LE) 300C/300C Touring (International Markets) 2005 - 2008 (LX) 300/Charger/Magnum **2005 - 2008 (WH) Grand Cherokee (International Markets)** 2005 - **2008** (WK) Grand Cherokee **2006 - 2008 (XH) Commander (International Markets)** 2006 - 2008 (XK) Commander NOTE: This bulletin applies to DR/L2/LE/LX/WH/WK models with a Power Sunroof (sales code GWA) built before October 31, 2007 (MDH1031XX) and XH models with a Power Sunroof (sales code GWF) built before December 19, 2007 (MDH1219XX) and XK models with a Power Sunroof (sales code GWF) built before November 07, 2007 (MDH1107XX). SYMPTOM/CONDITION: A ratcheting sound is heard from sunroof module as the glass approaches the full open position. DIAGNOSIS: Lower the headliner to view the rear of the sunroof module assembly. Inspect the cable conduit tube(s) located at the rear corners of the sunroof module assembly for a kinked condition. Kinked condition most frequently occurs at passenger rear corner. If a kinked conduit is discovered, perform the appropriate Repair Procedure based on the vehicle below. PARTS REQUIRED: REPAIR PROCEDURE - DRIL2/LE/LX/WH/WK: 1. Ensure the sunroof module is in the full closed position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > Customer Interest: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 15520 2. Remove M6 mounting bolts (4) at rear portion of sunroof module. 3. Remove the kinked cable conduit(s) from sunroof module retaining features starting from the end at the metal clip and work back to motor area, see (Fig 1). 4. Assemble new cable conduit, p/n 68003812AA, in reverse order of Step # 3) by inserting the flared end over the exposed end of the drive cable. Insure the flared end is sitting in the notch on the rear bulk head of sunroof module, (Fig 2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > Customer Interest: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 15521 5. Snap the cable conduit into the retaining features in the rear bulk head (5 places) with the end of the tube retained in spring clip on the aluminum guide. Ensure the clip is within the provided scribe lines on aluminum guide, (Fig 3). 6. Torque the mounting bolts to 9 Nm (80 in. lbs.). 7. Operate Sunroof module. 8. Install headliner. REPAIR PROCEDURE - XH/XK: 1. Put the sunroof in the closed or vent position. 2. Drop headliner right front corner, by removing the right side A-pillar trim, B-pillar trim sun visor, sun visor clip and rear view mirror. 3. Look at and/or feel the drive cable conduit in the radius above the drain hose this is where the conduit will be kinked. 4. Remove 2 sunroof mounting fasteners, (Fig 4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > Customer Interest: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 15522 5. Remove conduit from clip at side of sunroof module, (Fig 5). 6. Push the conduit up and inboard to release it from the retention feature on the front beam, (Fig 6) item 4. 7. Push the conduit up to release it from the additional retention features, (Fig. 6) item 2. 8. Pull the conduit out from over/off the drive cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > Customer Interest: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 15523 9. Slide the new conduit, p/n 68003816AA, back over the drive cable. See (Fig. 6) item 1, to ensure conduit is seated into notch to the rear of the steel drive cable tube. 10. Secure the conduit in the retention features shown in (Fig. 6). 11. Install the conduit in the side clip. 12. Operate the sunroof to ensure the ratcheting noise is eliminated. 13. Install the mounting bolts. 14. Install the headliner, A-pillar trim, sun visor and visor clip. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof Sunroof / Moonroof Cable Housing: All Technical Service Bulletins Body - Ratcheting Noise When Operating Sunroof NUMBER: 23-004-08 GROUP: Body DATE: January 16, 2008 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 23-045-06 DATED OCTOBER 14, 2006 AND 23-51-06 DATED NOVEMBER 4, 2006. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF WH/XH/L2 MODELS AND 2008 MODEL YEAR VEHICLES. SUBJECT: Ratcheting Sound During Sunroof Operation OVERVIEW: This bulletin involves replacing the sunroof drive cable conduit. MODELS: 2004 - **2008** (DR) Ram Truck **2007 (L2) 300C (China)** 2005 - **2008** (LE) 300C/300C Touring (International Markets) 2005 - 2008 (LX) 300/Charger/Magnum **2005 - 2008 (WH) Grand Cherokee (International Markets)** 2005 - **2008** (WK) Grand Cherokee **2006 - 2008 (XH) Commander (International Markets)** 2006 - 2008 (XK) Commander NOTE: This bulletin applies to DR/L2/LE/LX/WH/WK models with a Power Sunroof (sales code GWA) built before October 31, 2007 (MDH1031XX) and XH models with a Power Sunroof (sales code GWF) built before December 19, 2007 (MDH1219XX) and XK models with a Power Sunroof (sales code GWF) built before November 07, 2007 (MDH1107XX). SYMPTOM/CONDITION: A ratcheting sound is heard from sunroof module as the glass approaches the full open position. DIAGNOSIS: Lower the headliner to view the rear of the sunroof module assembly. Inspect the cable conduit tube(s) located at the rear corners of the sunroof module assembly for a kinked condition. Kinked condition most frequently occurs at passenger rear corner. If a kinked conduit is discovered, perform the appropriate Repair Procedure based on the vehicle below. PARTS REQUIRED: REPAIR PROCEDURE - DRIL2/LE/LX/WH/WK: 1. Ensure the sunroof module is in the full closed position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 15529 2. Remove M6 mounting bolts (4) at rear portion of sunroof module. 3. Remove the kinked cable conduit(s) from sunroof module retaining features starting from the end at the metal clip and work back to motor area, see (Fig 1). 4. Assemble new cable conduit, p/n 68003812AA, in reverse order of Step # 3) by inserting the flared end over the exposed end of the drive cable. Insure the flared end is sitting in the notch on the rear bulk head of sunroof module, (Fig 2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 15530 5. Snap the cable conduit into the retaining features in the rear bulk head (5 places) with the end of the tube retained in spring clip on the aluminum guide. Ensure the clip is within the provided scribe lines on aluminum guide, (Fig 3). 6. Torque the mounting bolts to 9 Nm (80 in. lbs.). 7. Operate Sunroof module. 8. Install headliner. REPAIR PROCEDURE - XH/XK: 1. Put the sunroof in the closed or vent position. 2. Drop headliner right front corner, by removing the right side A-pillar trim, B-pillar trim sun visor, sun visor clip and rear view mirror. 3. Look at and/or feel the drive cable conduit in the radius above the drain hose this is where the conduit will be kinked. 4. Remove 2 sunroof mounting fasteners, (Fig 4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 15531 5. Remove conduit from clip at side of sunroof module, (Fig 5). 6. Push the conduit up and inboard to release it from the retention feature on the front beam, (Fig 6) item 4. 7. Push the conduit up to release it from the additional retention features, (Fig. 6) item 2. 8. Pull the conduit out from over/off the drive cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 15532 9. Slide the new conduit, p/n 68003816AA, back over the drive cable. See (Fig. 6) item 1, to ensure conduit is seated into notch to the rear of the steel drive cable tube. 10. Secure the conduit in the retention features shown in (Fig. 6). 11. Install the conduit in the side clip. 12. Operate the sunroof to ensure the ratcheting noise is eliminated. 13. Install the mounting bolts. 14. Install the headliner, A-pillar trim, sun visor and visor clip. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Cable Housing: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set Steering Angle Sensor: All Technical Service Bulletins ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set NUMBER: 08-044-06 GROUP: Electrical DATE: October 07, 2006 SUBJECT: DTC C1240 - Steering Angle Sensor Over Travel Performance OVERVIEW: This bulletin involves the diagnosis and possible replacement of the Steering Angle Sensor. MODELS: 2007 (DR) Ram Truck NOTE: This bulletin applies to vehicle equipped with the Electronic Stability Program (sales code BNB) and built prior to October 03, 2006 (MDH 1003XX). SYMPTOM/CONDITION: The customer may experience an illumination on the instrument cluster of the "ABS" (Anti-Lock Brake System) and/or the "ESP / BAS" (Electronic Stability Program / Brake Assist System) Warning Lights. Investigation may reveal the presence of Diagnostic Trouble Code (DTC) C1240 Steering Angle Sensor Over Travel Performance (SAS). DIAGNOSIS: 1. Perform the diagnostic test procedure for DTC C1240. This diagnostic procedure can be found on TechCONNECT: select the SERVICE INFO tab > 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 340/445E5P AWAL > DIAGNOSIS and TESTING > C1240 - Steering Angle Sensor Over Travel Performance (SAS). 2. If the diagnostic test procedure for DTC C1240 determines that the Steering Angle Sensor is at fault, then perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Before starting this procedure, be certain that the front wheels are in the straight-ahead position. 1. Replace the steering column clockspring. Refer to TechCONNECT for detailed service procedures: select the SERVICE INFO tab > 8 - ELECTRICAL > RESTRAINTS > CLOCKSPRING > REMOVAL and INSTALLATION. 2. Clear offsets by initializing the ABS ECU using StarSCAN. 3. Perform the ABS VERIFICATION TEST. This test can be found in: 5 - BRAKES > 5 - BRAKES ELECTRICAL DIAGNOSTICS > ABS - EBC 3401445E5P AWAL > STANDARD PROCEDURE > ABS VERIFICATION TEST. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Cable Housing: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set > Page 15538 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Cable Housing: > 08-044-06 > Oct > 06 > ABS/TCS - ABS/ESP or BAS Lamps ON/DTC C1240 Set > Page 15544 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Diagrams Sunroof / Moonroof Motor: Diagrams Component ID: 215 Component : MOTOR/MODULE-SUNROOF Connector: Name : MOTOR/MODULE-SUNROOF Color : LT. GRAY # of pins : 10 Pin Description Circuit 1-2 SUNROOF VENT SWITCH SENSE Q4 20OR/YL 3 SUNROOF OPEN SWITCH SENSE Q3 20OR/TN 4 CAN B BUS (-) D54 20WT 5 CAN B BUS (+) D55 20WT/OR 6 GROUND Z964 14BK 7 SUNROOF CLOSE SWITCH SENSE Q5 20OR/LB 8 FUSED B(+) A310 14RD/LB 9-10 SUNROOF SWITCH SUPPLY Q6 20OR/LG Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Testing and Inspection > Component Tests and General Diagnostics Sunroof / Moonroof Motor: Component Tests and General Diagnostics MOTOR/MODULE - SUNROOF Any diagnosis of the power sunroof system should begin with the use of a scan tool and the proper Diagnostic Procedures Information. The scan tool can provide confirmation that the Controller Area Network (CAN) Data Bus is functional, that all of the electronic modules are sending and receiving the proper messages on the CAN Data Bus, and that the power sunroof motor is being sent the proper hard wired output by the sunroof switch. Refer to the appropriate diagnostic information. NOTE: If there is no sunroof movement when the "OPEN" or "CLOSED" button are pushed but the sunroof operates when the "VENT" button is pushed and held the sunroof motor/module is out of calibration. Complete the sunroof position calibration procedure prior to performing any sunroof diagnostics. The wire harness connectors for the sunroof motor/module are located above the vehicle headliner. Removal of the headliner may be necessary for access to the connector and proper diagnosis of the motor/module. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Verify that all other power accessories are in proper operating condition. If not, a common electrical problem may exist. 2. Disconnect the sunroof motor/module connector directly at the motor/module (not at the headliner in-line connector). Connect a test light between the harness connector pin 6 and a known good B+ circuit. The test light should illuminate brightly. If OK, go to STEP 3. If not OK repair the ground circuit as necessary. 3. Connect a test light between the harness connector pin 8 and a known good ground. The test light should illuminate brightly. If OK, go to STEP 4. If not OK repair the B+ circuit as necessary. 4. Using an ohmmeter check the sunroof switch feed circuit for continuity between the sunroof motor/module and sunroof switch. Continuity should be present. If OK replace the inoperative motor/module. If not OK repair the sunroof switch feed circuit as necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 15550 Sunroof / Moonroof Motor: Programming and Relearning MOTOR/MODULE INITIALIZATION NOTE: Verify the battery is in good condition prior to performing this procedure. Do not leave the vehicle on a battery charger while performing this procedure. If the voltage at the sunroof motor/module drops below 11 volts or exceeds 15 volts at anytime while this procedure is being performed, the motor/module initialization procedure will not be properly completed. 1. Turn the ignition to the RUN position. 2. Press the vent button on the power sunroof switch and hold until the sunroof glass panel has moved to the full vent position and the motor movement has stopped for at least 1 second. 3. Press the close position on the power sunroof switch and release. The sunroof glass panel should continue travel to the full closed position. This will be considered the first sunroof closed position in a series of four sunroof closes. 4. Press the vent button on the power sunroof switch and release. The sunroof glass panel should move to the full vent position. After the sunroof motor/module has stopped, press the close position on the power sunroof switch and release. The sunroof glass panel should continue travel to the full closed position. This will be considered the second sunroof closed position in a series of four sunroof closes. 5. Continue to move the sunroof glass to the "vent" then "closed" positions two more times so that the sunroof glass has moved to the closed position a total of four times starting with the first sunroof close in step 3. 6. Press the open position on the power sunroof switch and release. The sunroof glass panel should continue travel to the full open position. 7. Press the close position on the power sunroof switch and release. The sunroof glass panel should continue travel to the full closed position. This will be considered the first sunroof closed position in a series of five sunroof closes. 8. Press the open position on the power sunroof switch and release. The sunroof glass panel should move to the full open position. After the sunroof motor/module has stopped, press the close position on the power sunroof switch and release. The sunroof glass panel should continue travel to the full closed position. Continue to move the sunroof glass to the "open" then "closed" position four more times so that the sunroof glass has moved to the closed position a total of five times starting with the first sunroof close in step 7. Verify proper EFL calibration by placing a standard pencil at the front of the sunroof and then moving the sunroof to the full closed position. The sunroof should reverse direction upon contact without damage to the pencil. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Testing and Inspection > Page 15551 Sunroof / Moonroof Motor: Adjustments SUNROOF POSITION CALIBRATION Press the power sunroof switch (Open, Closed, and Vent). If no movement occurs when either the open switch or closed switch is pressed, but the system does move when the vent button is pressed and held, the system is not calibrated. Perform the following procedure to position calibrate the power sunroof system. 1. Turn the ignition to the RUN position. 2. Press the vent button on the power sunroof switch and hold until the sunroof glass panel has moved to the full vent position and the motor movement has stopped for at least 1 second. 3. Press the close switch on the power sunroof switch and hold for a moment (at least 100ms) and release. The sunroof glass panel should continue travel to the full close position. If the sunroof glass panel does not return to the full close position, refer to the appropriate diagnostic information for full system diagnosis. 4. Verify proper system operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Sunroof Motor With Control Unit - Removal Sunroof / Moonroof Motor: Service and Repair Sunroof Motor With Control Unit - Removal REMOVAL WARNING: Do not attempt to move or reposition the sunroof glass panel or drive cables with the motor/module removed. Vehicle/sunroof damage or personal injury may result. WARNING: The sunroof must first be calibrated and the Motor/Module Initialization Procedure must be completed any time a sunroof motor/module is replaced with a new component. Failure to perform this procedure could result in vehicle damage and/or personal injury. 1. Disconnect the battery negative cable. 2. Remove the vehicle headliner. 3. Remove the power sunroof motor/module electrical connector (2). 4. Remove the retaining screws (3) and remove the motor/module (1) from the vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Sunroof Motor With Control Unit - Removal > Page 15554 Sunroof / Moonroof Motor: Service and Repair Sunroof Motor With Control Unit - Installation INSTALLATION WARNING: Do not attempt to move or reposition the sunroof glass panel or drive cables with the motor/module removed. Vehicle/sunroof damage or personal injury may result. WARNING: The sunroof must first be calibrated and the Motor/Module Initialization Procedure must be completed any time a sunroof motor/module is replaced with a new component. Failure to perform this procedure could result in vehicle damage and/or personal injury. 1. Position the power sunroof motor/module (1) in the vehicle. 2. Install the motor/module retaining screws (3). Tighten the screws to 4 Nm (35 in. lbs.). 3. Connect the motor/module electrical connector (2). 4. Partially install the vehicle headliner and connect all remaining sunroof electrical connectors. 5. Connect the battery negative cable. 6. Perform the sunroof position calibration. 7. Perform the Motor/Module Initialization Procedure. 8. Complete the vehicle headliner installation. 9. Verify proper operation of the power sunroof system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations Sunroof / Moonroof Switch: Locations Component ID: 489 Component : SWITCH-SUNROOF Connector: Name : SWITCH-SUNROOF Color : BLACK # of pins : 4 A SUNROOF VENT SWITCH SENSE Q4 20OR/YL B SUNROOF SWITCH SUPPLY Q6 20OR/LG C SUNROOF OPEN SWITCH SENSE Q3 20OR/TN D SUNROOF CLOSE SWITCH SENSE Q5 20OR/LB Component Location - 53 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 15558 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 15559 Sunroof / Moonroof Switch: Diagrams Component ID: 489 Component : SWITCH-SUNROOF Connector: Name : SWITCH-SUNROOF Color : BLACK # of pins : 4 A SUNROOF VENT SWITCH SENSE Q4 20OR/YL B SUNROOF SWITCH SUPPLY Q6 20OR/LG C SUNROOF OPEN SWITCH SENSE Q3 20OR/TN D SUNROOF CLOSE SWITCH SENSE Q5 20OR/LB Component Location - 53 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 15560 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Description and Operation > Description Sunroof / Moonroof Switch: Description and Operation Description DESCRIPTION The power sunroof switch (3) is a combination push-button and rocker switch module mounted in the overhead console. The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/module assembly. The sunroof switch performs the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed) The power sunroof switch is part of the overhead console assembly and cannot be replaced separately. If the switch is damaged or inoperative the overhead console must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Description and Operation > Description > Page 15563 Sunroof / Moonroof Switch: Description and Operation Operation OPERATION The power sunroof switch is hard wired to the sunroof motor/module assembly. The switch receives battery current from the motor/module when the ignition switch is in the RUN and ACCESSORY positions. When one of the switch positions is pressed it sends battery current back to the motor/module, signaling it to move the power sunroof to the appropriate position. The motor/module will perform one of the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Description and Operation > Page 15564 Sunroof / Moonroof Switch: Testing and Inspection SWITCH - POWER SUNROOF For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. If completing the appropriate diagnostic information results in the sunroof switch being inoperative, perform the following test prior to switch replacement. 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console. 3. Disconnect the power sunroof switch wire harness connector. 4. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. Refer to the POWER SUNROOF SWITCH CONTINUITY TABLE. If OK, inspect the wiring harness and connectors for damage. Use a scan tool and the proper Diagnostic Procedures Information to complete diagnosis of the power sunroof system. If not OK, replace the overhead console. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Removal Sunroof / Moonroof Track: Service and Repair Removal REMOVAL 1. Place the sunroof in the vent position. 2. Remove the sunroof assembly. 3. Remove the motor. 4. Remove the glass. 5. Remove the wind deflector. 6. Separate the drain channel arms (2) from the guide mechanisms (1) one at a time. CAUTION: Do not pry the channel arms apart at the same time or you could break the drain channel. 7. Slide the drain channel rearward out of the way. 8. Remove the hard stop screw from the frame. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Removal > Page 15569 9. Push the drive cable and guide plate forward past the hard stop screw location until the glass guide comes loose. 10. Rotate the guide (1) up and out of the front beam (3) and release the front foot (2) from the channel guide. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Removal > Page 15570 Sunroof / Moonroof Track: Service and Repair Installation INSTALLATION 1. With the drive cable plate aligned insert the front foot (2) into the guide channel and engage the feet with the front beam (3). 2. Rotate the guide plate (1) inboard until the feet of the guide are engaged into the front beam (2). 3. Push the guide assembly (1) and drive cable rearward past the hard stop location. 4. Install the hard stop screw (2) and push the drive cable and guide assembly (1) up against the hard stop screw (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Removal > Page 15571 5. Verify that the opposite guide assembly is also positioned up against the hard stop screw. 6. Install the wind deflector as necessary. 7. Install the motor as necessary. 8. Install the drain channel arms (2) into the mechanism (1) holes one at a time with the reinforcements on the inside of mechanism arms. CAUTION: Do not pry the channel arms apart at the same time or you could break the drain channel. 9. Install the sunroof assembly into the vehicle. 10. Perform the sunroof position calibration. 11. Perform the Excessive Force Limitation (EFL) calibration. 12. Install the glass as necessary. 13. Adjust sunroof glass to fit flush with roof lin. 14. Verify proper operation of the power sunroof system. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Removal Sunroof / Moonroof Windguard: Service and Repair Removal REMOVAL 1. Open the sunroof fully. 2. Remove the strap screws (2) from the beam area release the strap (3). 3. Rotate the deflector up and remove springs (2) from the holes in the frame (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Removal > Page 15576 Sunroof / Moonroof Windguard: Service and Repair Installation INSTALLATION 1. Position the deflector spring arms (2) into the holes of the frame (1). 2. Rotate the deflector down, attach the straps (3) and install the strap screws (2) into the front beam. 3. Verify sunroof operation and alignment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Channel-Drain Sunroof / Moonroof Drain: Service and Repair Channel-Drain Removal REMOVAL 1. Remove glass panel. 2. Separate the drain channel arms (2) from the guide mechanisms (1) one at a time. CAUTION: Do not pry the channel arms apart at the same time or you could break the drain channel. 3. Carefully slide the drain channel (1) forward to the notches (2) in the frame and remove from the vehicle. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Channel-Drain > Page 15581 1. Carefully position the drain channel (1) into the notches (2) in the frame and slide rearward. 2. Install the drain channel arms (2) into the mechanism (1) holes one at a time with the reinforcements on the inside of mechanism arms. CAUTION: Do not pry the channel arms apart at the same time or you could break the drain channel. 3. Install the sunroof glass. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Channel-Drain > Page 15582 Sunroof / Moonroof Drain: Service and Repair Hose-Drain Removal REMOVAL FRONT HOSES 1. Remove headliner. 2. Disconnect the drain hose from the sunroof housing (1). 3. Separate the lower tube from the grommet in the body (3). 4. Drain any liquid from hose connection, if necessary. 5. Release the clips (2) and remove the tube. REAR HOUSING HOSE 1. Remove headliner. 2. Disconnect the drain hose from the sunroof housing (1). * Front tube shown, rear tube similar. 3. Drain any liquid from hose connection, if necessary. 4. Release the push pin fasteners (2) and separate the lower tube from the grommet in the body (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Channel-Drain > Page 15583 Installation INSTALLATION FRONT HOSES 1. Position the lower portion through the grommet in the body (3). 2. Connect the new drain tube to the sunroof housing (1) and test drainage. 3. Position the tube support clips (2) and seat fully. 4. Install headliner. REAR HOUSING HOSE 1. Install the rear tube and seat the push pin fasteners (2) fully. * Front tube shown, rear similar. 2. Position the lower portion through the grommet in the body (3). 3. Connect the new drain tube to the sunroof housing (1) and test drainage. 4. Install headliner. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Interior Trim Panel > Component Information > Service and Repair > Cover-Guide Mechanism Sunroof / Moonroof Interior Trim Panel: Service and Repair Cover-Guide Mechanism Removal REMOVAL 1. Move the glass panel to the full closed position. 2. Slide sunshade rearward to the open position. 3. Separate the mechanism covers (2) from the tabs (1) on the glass panel. 4. Hold both mechanism covers down and open the sunroof fully. 5. Slide the mechanism covers (1) out the front of the guide in the frame (2). Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Interior Trim Panel > Component Information > Service and Repair > Cover-Guide Mechanism > Page 15588 1. With the sunroof in the open position, snap the mechanism cover (2) into the lower guide channel. 2. Hold down each cover and close the sunroof. 3. Snap the upper portion of the cover (2) into the retaining clips (1) on the glass panel between the locating features. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Interior Trim Panel > Component Information > Service and Repair > Cover-Guide Mechanism > Page 15589 Sunroof / Moonroof Interior Trim Panel: Service and Repair Trim Ring Removal REMOVAL 1. Remove the headliner. 2. Remove the 12 nuts (1) and roll the trim ring off the headliner off the retaining flanges (2). Installation INSTALLATION 1. Position trim ring support flanges (2) over the headliner and seat the trim ring fully. 2. Install the 12 nuts (1) onto the support studs. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments Sunroof / Moonroof Panel: Adjustments ADJUSTMENT 1. Move the sunshade rearward to the open position. 2. Separate the mechanism covers (2) from the tabs (1) on the glass panel. 3. Verify the sunroof glass panel is in the fully closed position. 4. Loosen the forward attaching screws (3) on each side enough to permit the front of the glass to adjust up or down. 5. Adjust the front surface of the sunroof glass panel 0.00 mm to 2 mm (0.00 in. to 0.08 in.) below the top surface of the roof. 6. Tighten the front glass panel attaching screws to 3.5 Nm (30 in. lbs.). 7. Loosen the rear screws (3) on each side enough to make the rear adjustment. 8. Adjust the rear surface of the sunroof glass panel 0.00 mm to 2 mm (0.03 in. to 0.08 in.) above the top surface of the roof. 9. Tighten the rear glass panel attaching screws to 3.5 Nm (30 in. lbs.). 10. Check for proper fit. If not OK, repeat glass panel adjustment. 11. Position the mechanism covers (2) over the glass tabs (1) between the locating features and seat fully. 12. Verify sunroof operation and alignment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Removal Sunroof / Moonroof Panel: Service and Repair Removal REMOVAL 1. Move the glass panel to the full closed position. 2. Slide sunshade rearward to the open position. 3. Separate the mechanism covers (2) from the tabs (1) on the glass panel. 4. Remove the glass panel screws (3). 5. Lift off glass panel and remove from vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Removal > Page 15595 Sunroof / Moonroof Panel: Service and Repair Installation INSTALLATION 1. Position glass panel on to mechanism lift arms. CAUTION: Verify that the retaining tabs are located on the INSIDE of the guide mechanism arms. 2. Start the attaching screws (3). 3. Connect a 12v power supply and verify that the sunroof is in the closed position. 4. Adjust sunroof glass to fit flush with roof line. 5. Tighten the screws (3) to 3.5 Nm (30 in. lbs.). 6. Position the mechanism covers (2) over the glass tabs (1) between the locating features and seat fully. 7. Verify sunroof operation and alignment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Headrest Head Rest: Service and Repair Headrest Removal REMOVAL 1. Raise the headrest. 2. Press the headrest release button and remove the headrest. Installation INSTALLATION 1. Position the headrest. 2. Press the release button and install the headrest. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Headrest > Page 15601 Head Rest: Service and Repair Headrest Sleeve Removal REMOVAL 1. Remove the headrest. 2. Grasp the sleeves and pull up and out of the seat back to remove. Installation INSTALLATION 1. Position each headrest sleeve into correct seat back hole and press into place fully. 2. Install the headrest. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions Memory Positioning Systems: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15606 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15607 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15608 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15609 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15610 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15611 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15612 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15613 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15614 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15615 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15616 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15617 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15618 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15619 Memory Positioning Systems: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15620 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15621 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15622 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 15623 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Motor-Seat Adjuster-Driver Horizontal Power Seat Motor: Locations Motor-Seat Adjuster-Driver Horizontal Component ID: 221 Component : MOTOR-SEAT ADJUSTER-DRIVER HORIZONTAL Connector: Name : MOTOR-SEAT ADJUSTER-DRIVER HORIZONTAL Color : # of pins : 2 Qualifier : (HD) Pin Description Circuit 1 DRIVER SEAT HORIZONTAL REARWARD DRIVER P17 12LG/DG 2 DRIVER SEAT HORIZONTAL FORWARD DRIVER P15 12LG/BR Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Motor-Seat Adjuster-Driver Horizontal > Page 15628 Connector: Name : MOTOR-SEAT ADJUSTER-DRIVER HORIZONTAL Color : BLACK # of pins : 5 Qualifier : (LD) Pin Description Circuit 1 DRIVER SEAT HORIZONTAL FORWARD DRIVER P15 12LG/WT 2-3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Motor-Seat Adjuster-Driver Horizontal > Page 15629 5 DRIVER SEAT HORIZONTAL REARWARD DRIVER P17 12LG/DG Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Motor-Seat Adjuster-Driver Horizontal > Page 15630 Power Seat Motor: Locations Motor-Seat Adjuster-Front Driver Vertical Component ID: 222 Component : MOTOR-SEAT ADJUSTER-FRONT DRIVER VERTICAL Connector: Name : MOTOR-SEAT ADJUSTER-FRONT DRIVER VERTICAL Color : # of pins : 2 Qualifier : (HD) Pin Description Circuit 1 DRIVER SEAT FRONT UP DRIVER P19 12LG/LB 2 DRIVER SEAT FRONT DOWN DRIVER P21 12LG/TN Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Motor-Seat Adjuster-Driver Horizontal > Page 15631 Connector: Name : MOTOR-SEAT ADJUSTER-FRONT DRIVER VERTICAL Color : BLACK # of pins : 5 Qualifier : (LD) Pin Description Circuit 1 DRIVER SEAT FRONT DOWN DRIVER P21 12LG/TN 2-3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Motor-Seat Adjuster-Driver Horizontal > Page 15632 5 DRIVER SEAT FRONT UP DRIVER P19 12LG/LB Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Motor-Seat Adjuster-Driver Horizontal > Page 15633 Power Seat Motor: Locations Motor-Seat Adjuster-Front Passenger Vertical Component ID: 223 Component : MOTOR-SEAT ADJUSTER-FRONT PASSENGER VERTICAL Connector: Name : MOTOR-SEAT ADJUSTER-FRONT PASSENGER VERTICAL Color : # of pins : 2 Pin Description Circuit 1 PASSENGER SEAT FRONT DOWN DRIVER P18 12LG/OR 2 PASSENGER SEAT FRONT UP DRIVER P20 12LG/LB Component Location - 67 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Motor-Seat Adjuster-Driver Horizontal > Page 15634 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Motor-Seat Adjuster-Driver Horizontal > Page 15635 Power Seat Motor: Locations Motor-Seat Adjuster-Passenger Horizontal Component ID: 224 Component : MOTOR-SEAT ADJUSTER-PASSENGER HORIZONTAL Connector: Name : MOTOR-SEAT ADJUSTER-PASSENGER HORIZONTAL Color : # of pins : 2 Pin Description Circuit 1 PASSENGER SEAT HORIZONTAL REARWARD DRIVER P16 12LG/BR 2 PASSENGER SEAT HORIZONTAL FORWARD DRIVER P14 12LG/OR Component Location - 67 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Motor-Seat Adjuster-Driver Horizontal > Page 15636 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Motor-Seat Adjuster-Driver Horizontal > Page 15637 Power Seat Motor: Locations Motor-Seat Adjuster-Driver Horizontal Component ID: 221 Component : MOTOR-SEAT ADJUSTER-DRIVER HORIZONTAL Connector: Name : MOTOR-SEAT ADJUSTER-DRIVER HORIZONTAL Color : # of pins : 2 Qualifier : (HD) Pin Description Circuit 1 DRIVER SEAT HORIZONTAL REARWARD DRIVER P17 12LG/DG 2 DRIVER SEAT HORIZONTAL FORWARD DRIVER P15 12LG/BR Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Motor-Seat Adjuster-Driver Horizontal > Page 15638 Connector: Name : MOTOR-SEAT ADJUSTER-DRIVER HORIZONTAL Color : BLACK # of pins : 5 Qualifier : (LD) Pin Description Circuit 1 DRIVER SEAT HORIZONTAL FORWARD DRIVER P15 12LG/WT 2-3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Motor-Seat Adjuster-Driver Horizontal > Page 15639 5 DRIVER SEAT HORIZONTAL REARWARD DRIVER P17 12LG/DG Component Location - 66 Motor-Seat Adjuster-Front Driver Vertical Component ID: 222 Component : MOTOR-SEAT ADJUSTER-FRONT DRIVER VERTICAL Connector: Name : MOTOR-SEAT ADJUSTER-FRONT DRIVER VERTICAL Color : # of pins : 2 Qualifier : (HD) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Motor-Seat Adjuster-Driver Horizontal > Page 15640 Pin Description Circuit 1 DRIVER SEAT FRONT UP DRIVER P19 12LG/LB 2 DRIVER SEAT FRONT DOWN DRIVER P21 12LG/TN Component Location - 66 Connector: Name : MOTOR-SEAT ADJUSTER-FRONT DRIVER VERTICAL Color : BLACK # of pins : 5 Qualifier : (LD) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Motor-Seat Adjuster-Driver Horizontal > Page 15641 Pin Description Circuit 1 DRIVER SEAT FRONT DOWN DRIVER P21 12LG/TN 2-3-4-5 DRIVER SEAT FRONT UP DRIVER P19 12LG/LB Component Location - 66 Motor-Seat Adjuster-Front Passenger Vertical Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Motor-Seat Adjuster-Driver Horizontal > Page 15642 Component ID: 223 Component : MOTOR-SEAT ADJUSTER-FRONT PASSENGER VERTICAL Connector: Name : MOTOR-SEAT ADJUSTER-FRONT PASSENGER VERTICAL Color : # of pins : 2 Pin Description Circuit 1 PASSENGER SEAT FRONT DOWN DRIVER P18 12LG/OR 2 PASSENGER SEAT FRONT UP DRIVER P20 12LG/LB Component Location - 67 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Motor-Seat Adjuster-Driver Horizontal > Page 15643 Motor-Seat Adjuster-Passenger Horizontal Component ID: 224 Component : MOTOR-SEAT ADJUSTER-PASSENGER HORIZONTAL Connector: Name : MOTOR-SEAT ADJUSTER-PASSENGER HORIZONTAL Color : # of pins : 2 Pin Description Circuit Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Motor-Seat Adjuster-Driver Horizontal > Page 15644 1 PASSENGER SEAT HORIZONTAL REARWARD DRIVER P16 12LG/BR 2 PASSENGER SEAT HORIZONTAL FORWARD DRIVER P14 12LG/OR Component Location - 67 Motor-Seat Adjuster-Rear Driver Vertical Component ID: 225 Component : MOTOR-SEAT ADJUSTER-REAR DRIVER VERTICAL Connector: Name : MOTOR-SEAT ADJUSTER-REAR DRIVER VERTICAL Color : # of pins : 2 Qualifier : (HD) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Motor-Seat Adjuster-Driver Horizontal > Page 15645 Pin Description Circuit 1 DRIVER SEAT REAR UP DRIVER P11 12LG/YL 2 DRIVER SEAT REAR DOWN DRIVER P13 12LG/OR Component Location - 66 Connector: Name : MOTOR-SEAT ADJUSTER-REAR DRIVER VERTICAL Color : BLACK # of pins : 5 Qualifier : (LD) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Motor-Seat Adjuster-Driver Horizontal > Page 15646 Pin Description Circuit 1 DRIVER SEAT REAR UP DRIVER P11 12LG/YL 2-3-4-5 DRIVER SEAT REAR DOWN DRIVER P13 12LG/OR Component Location - 66 Motor-Seat Adjuster-Rear Passenger Vertical Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Motor-Seat Adjuster-Driver Horizontal > Page 15647 Component ID: 226 Component : MOTOR-SEAT ADJUSTER-REAR PASSENGER VERTICAL Connector: Name : MOTOR-SEAT ADJUSTER-REAR PASSENGER VERTICAL Color : # of pins : 2 Pin Description Circuit 1 PASSENGER SEAT REAR DOWN DRIVER P10 12LG/TN 2 PASSENGER SEAT REAR UP DRIVER P12 12LG/YL Component Location - 67 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Motor-Seat Adjuster-Driver Horizontal > Page 15648 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Motor-Seat Adjuster-Driver Horizontal Power Seat Motor: Diagrams Motor-Seat Adjuster-Driver Horizontal Component ID: 221 Component : MOTOR-SEAT ADJUSTER-DRIVER HORIZONTAL Connector: Name : MOTOR-SEAT ADJUSTER-DRIVER HORIZONTAL Color : # of pins : 2 Qualifier : (HD) Pin Description Circuit 1 DRIVER SEAT HORIZONTAL REARWARD DRIVER P17 12LG/DG 2 DRIVER SEAT HORIZONTAL FORWARD DRIVER P15 12LG/BR Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Motor-Seat Adjuster-Driver Horizontal > Page 15651 Connector: Name : MOTOR-SEAT ADJUSTER-DRIVER HORIZONTAL Color : BLACK # of pins : 5 Qualifier : (LD) Pin Description Circuit 1 DRIVER SEAT HORIZONTAL FORWARD DRIVER P15 12LG/WT 2-3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Motor-Seat Adjuster-Driver Horizontal > Page 15652 5 DRIVER SEAT HORIZONTAL REARWARD DRIVER P17 12LG/DG Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Motor-Seat Adjuster-Driver Horizontal > Page 15653 Power Seat Motor: Diagrams Motor-Seat Adjuster-Front Driver Vertical Component ID: 222 Component : MOTOR-SEAT ADJUSTER-FRONT DRIVER VERTICAL Connector: Name : MOTOR-SEAT ADJUSTER-FRONT DRIVER VERTICAL Color : # of pins : 2 Qualifier : (HD) Pin Description Circuit 1 DRIVER SEAT FRONT UP DRIVER P19 12LG/LB 2 DRIVER SEAT FRONT DOWN DRIVER P21 12LG/TN Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Motor-Seat Adjuster-Driver Horizontal > Page 15654 Connector: Name : MOTOR-SEAT ADJUSTER-FRONT DRIVER VERTICAL Color : BLACK # of pins : 5 Qualifier : (LD) Pin Description Circuit 1 DRIVER SEAT FRONT DOWN DRIVER P21 12LG/TN 2-3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Motor-Seat Adjuster-Driver Horizontal > Page 15655 5 DRIVER SEAT FRONT UP DRIVER P19 12LG/LB Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Motor-Seat Adjuster-Driver Horizontal > Page 15656 Power Seat Motor: Diagrams Motor-Seat Adjuster-Front Passenger Vertical Component ID: 223 Component : MOTOR-SEAT ADJUSTER-FRONT PASSENGER VERTICAL Connector: Name : MOTOR-SEAT ADJUSTER-FRONT PASSENGER VERTICAL Color : # of pins : 2 Pin Description Circuit 1 PASSENGER SEAT FRONT DOWN DRIVER P18 12LG/OR 2 PASSENGER SEAT FRONT UP DRIVER P20 12LG/LB Component Location - 67 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Motor-Seat Adjuster-Driver Horizontal > Page 15657 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Motor-Seat Adjuster-Driver Horizontal > Page 15658 Power Seat Motor: Diagrams Motor-Seat Adjuster-Passenger Horizontal Component ID: 224 Component : MOTOR-SEAT ADJUSTER-PASSENGER HORIZONTAL Connector: Name : MOTOR-SEAT ADJUSTER-PASSENGER HORIZONTAL Color : # of pins : 2 Pin Description Circuit 1 PASSENGER SEAT HORIZONTAL REARWARD DRIVER P16 12LG/BR 2 PASSENGER SEAT HORIZONTAL FORWARD DRIVER P14 12LG/OR Component Location - 67 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Motor-Seat Adjuster-Driver Horizontal > Page 15659 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Motor-Seat Adjuster-Driver Horizontal > Page 15660 Power Seat Motor: Diagrams Motor-Seat Adjuster-Driver Horizontal Component ID: 221 Component : MOTOR-SEAT ADJUSTER-DRIVER HORIZONTAL Connector: Name : MOTOR-SEAT ADJUSTER-DRIVER HORIZONTAL Color : # of pins : 2 Qualifier : (HD) Pin Description Circuit 1 DRIVER SEAT HORIZONTAL REARWARD DRIVER P17 12LG/DG 2 DRIVER SEAT HORIZONTAL FORWARD DRIVER P15 12LG/BR Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Motor-Seat Adjuster-Driver Horizontal > Page 15661 Connector: Name : MOTOR-SEAT ADJUSTER-DRIVER HORIZONTAL Color : BLACK # of pins : 5 Qualifier : (LD) Pin Description Circuit 1 DRIVER SEAT HORIZONTAL FORWARD DRIVER P15 12LG/WT 2-3-4-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Motor-Seat Adjuster-Driver Horizontal > Page 15662 5 DRIVER SEAT HORIZONTAL REARWARD DRIVER P17 12LG/DG Component Location - 66 Motor-Seat Adjuster-Front Driver Vertical Component ID: 222 Component : MOTOR-SEAT ADJUSTER-FRONT DRIVER VERTICAL Connector: Name : MOTOR-SEAT ADJUSTER-FRONT DRIVER VERTICAL Color : # of pins : 2 Qualifier : (HD) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Motor-Seat Adjuster-Driver Horizontal > Page 15663 Pin Description Circuit 1 DRIVER SEAT FRONT UP DRIVER P19 12LG/LB 2 DRIVER SEAT FRONT DOWN DRIVER P21 12LG/TN Component Location - 66 Connector: Name : MOTOR-SEAT ADJUSTER-FRONT DRIVER VERTICAL Color : BLACK # of pins : 5 Qualifier : (LD) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Motor-Seat Adjuster-Driver Horizontal > Page 15664 Pin Description Circuit 1 DRIVER SEAT FRONT DOWN DRIVER P21 12LG/TN 2-3-4-5 DRIVER SEAT FRONT UP DRIVER P19 12LG/LB Component Location - 66 Motor-Seat Adjuster-Front Passenger Vertical Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Motor-Seat Adjuster-Driver Horizontal > Page 15665 Component ID: 223 Component : MOTOR-SEAT ADJUSTER-FRONT PASSENGER VERTICAL Connector: Name : MOTOR-SEAT ADJUSTER-FRONT PASSENGER VERTICAL Color : # of pins : 2 Pin Description Circuit 1 PASSENGER SEAT FRONT DOWN DRIVER P18 12LG/OR 2 PASSENGER SEAT FRONT UP DRIVER P20 12LG/LB Component Location - 67 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Motor-Seat Adjuster-Driver Horizontal > Page 15666 Motor-Seat Adjuster-Passenger Horizontal Component ID: 224 Component : MOTOR-SEAT ADJUSTER-PASSENGER HORIZONTAL Connector: Name : MOTOR-SEAT ADJUSTER-PASSENGER HORIZONTAL Color : # of pins : 2 Pin Description Circuit Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Motor-Seat Adjuster-Driver Horizontal > Page 15667 1 PASSENGER SEAT HORIZONTAL REARWARD DRIVER P16 12LG/BR 2 PASSENGER SEAT HORIZONTAL FORWARD DRIVER P14 12LG/OR Component Location - 67 Motor-Seat Adjuster-Rear Driver Vertical Component ID: 225 Component : MOTOR-SEAT ADJUSTER-REAR DRIVER VERTICAL Connector: Name : MOTOR-SEAT ADJUSTER-REAR DRIVER VERTICAL Color : # of pins : 2 Qualifier : (HD) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Motor-Seat Adjuster-Driver Horizontal > Page 15668 Pin Description Circuit 1 DRIVER SEAT REAR UP DRIVER P11 12LG/YL 2 DRIVER SEAT REAR DOWN DRIVER P13 12LG/OR Component Location - 66 Connector: Name : MOTOR-SEAT ADJUSTER-REAR DRIVER VERTICAL Color : BLACK # of pins : 5 Qualifier : (LD) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Motor-Seat Adjuster-Driver Horizontal > Page 15669 Pin Description Circuit 1 DRIVER SEAT REAR UP DRIVER P11 12LG/YL 2-3-4-5 DRIVER SEAT REAR DOWN DRIVER P13 12LG/OR Component Location - 66 Motor-Seat Adjuster-Rear Passenger Vertical Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Motor-Seat Adjuster-Driver Horizontal > Page 15670 Component ID: 226 Component : MOTOR-SEAT ADJUSTER-REAR PASSENGER VERTICAL Connector: Name : MOTOR-SEAT ADJUSTER-REAR PASSENGER VERTICAL Color : # of pins : 2 Pin Description Circuit 1 PASSENGER SEAT REAR DOWN DRIVER P10 12LG/TN 2 PASSENGER SEAT REAR UP DRIVER P12 12LG/YL Component Location - 67 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Motor-Seat Adjuster-Driver Horizontal > Page 15671 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Switch-Seat-Driver Power Seat Switch: Diagrams Switch-Seat-Driver Component ID: 484 Component : SWITCH-SEAT-DRIVER Connector: Name : SWITCH-SEAT-DRIVER Color : # of pins : 12 Qualifier : (HD) A FUSED B(+) A210 12OR/RD B GROUND Z939 14BK C-E DRIVER SEAT REAR UP DRIVER P11 12LG/YL F-G GROUND Z939 14BK H FUSED B(+) A210 12OR/RD J DRIVER SEAT REAR DOWN DRIVER P13 12LG/OR K DRIVER SEAT HORIZONTAL REARWARD DRIVER P17 12LG/DG L DRIVER SEAT HORIZONTAL FORWARD DRIVER P15 12LG/BR M DRIVER SEAT FRONT UP DRIVER P19 12LG/LB N DRIVER SEAT FRONT DOWN DRIVER P21 12LG/TN Connector: Name : SWITCH-SEAT-DRIVER Color : GRAY # of pins : 8 Qualifier : (LD) Gender : MALE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Switch-Seat-Driver > Page 15676 Pin Description Circuit 1 DRIVER SEAT FRONT UP DRIVER P19 12LG/LB 2 GROUND Z939 14BK 3 DRIVER SEAT HORIZONTAL FORWARD DRIVER P15 12LG/WT 4 FUSED B(+) A210 12OR/RD 5 DRIVER SEAT REAR UP DRIVER P11 12LG/YL 6 DRIVER SEAT HORIZONTAL REARWARD DRIVER P17 12LG/DG 7 DRIVER SEAT REAR DOWN DRIVER P13 12LG/OR 8 DRIVER SEAT FRONT DOWN DRIVER P21 12LG/TN Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Switch-Seat-Driver > Page 15677 Power Seat Switch: Diagrams Switch-Seat-Passenger Component ID: 485 Component : SWITCH-SEAT-PASSENGER Connector: Name : SWITCH-SEAT-PASSENGER Color : # of pins : 12 A FUSED B(+) A210 12OR/RD B GROUND Z939 14BK C-E PASSENGER SEAT REAR UP DRIVER P12 12LG/YL F-G GROUND Z939 14BK H FUSED B(+) A210 12OR/RD J PASSENGER SEAT REAR DOWN DRIVER P10 12LG/TN K PASSENGER SEAT HORIZONTAL REARWARD DRIVER P16 12LG/BR L PASSENGER SEAT HORIZONTAL FORWARD DRIVER P14 12LG/OR M PASSENGER SEAT FRONT UP DRIVER P20 12LG/LB N PASSENGER SEAT FRONT DOWN DRIVER P18 12LG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Description and Operation > Description Power Seat Switch: Description and Operation Description DESCRIPTION The power seats on this vehicle can be adjusted in eight different directions, up, down, front up, front down, rear up, rear down, rearward and forward. The power seat switch is located on the outboard side of the seat cushion on the seat cushion side shield. The individual switches in the power seat switch assembly cannot be repaired. If one switch is damaged or inoperative, the entire power seat switch assembly must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Description and Operation > Description > Page 15680 Power Seat Switch: Description and Operation Operation OPERATION When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Description and Operation > Page 15681 Power Seat Switch: Testing and Inspection POWER SEAT SWITCH For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. 3. Using an ohmmeter to test the continuity of the power seat switches in each position. If OK Refer to Power Seat Track Testing. If not OK, replace the inoperative power seat switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Removal Power Seat Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side shield from the seat. 3. Pull the switch bezel or side shield unit (1) out from the seat far enough to access the switch wire harness connector. Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module (2). 4. Remove the screws (3) that secure the power seat switch (2) to the side shield unit (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Removal > Page 15684 Power Seat Switch: Service and Repair Installation INSTALLATION 1. Position the power seat switch (2) on the seat cushion side shield (1) and install the screws (3). 2. Connect the electrical connector. 3. Install the seat cushion side shield on the seat. 4. Connect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Center Armrest / Seat Back Seat Back: Service and Repair Center Armrest / Seat Back Removal REMOVAL 1. Before proceeding with the following repair procedure, review all warnings and cautions. NOTE: Do not reuse the seat fasteners, always replace with new ones. 2. Remove the center seat. 3. Disconnect the storage bin/cushion cover j-straps and position aside. 4. Remove and discard the hinge bolts (2) and separate the seat back from the storage bin/cushion (1). Installation INSTALLATION 1. Before proceeding with the following repair procedure, review all warnings and cautions. NOTE: Do not reuse the seat fasteners, always replace with new ones. 2. Install the seat back onto the storage bin/cushion (1) and install new hinge bolts (2). 3. Tighten the hinge to storage bin/cushion bolts (2) to 25 Nm (18 ft. lbs.). 4. Connect the storage bin/cushion cover j-straps. 5. Install the center seat. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Center Armrest / Seat Back > Page 15689 Seat Back: Service and Repair Center Seat Back Inertia Hinge Cover Removal REMOVAL NOTE: Free pivot hinge cover is removed with the free pivot hinge . 1. For the inertia hinge cover disconnect the zip strip (1). 2. Position aside the storage bin/cushion cover (4). 3. Remove the pivot bolt (5). 4. Open the hinge cover at the bottom and remove the hinge cover (1). Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Center Armrest / Seat Back > Page 15690 NOTE: Free pivot hinge cover is installed with the free pivot hinge. 1. Position the hinge cover (1) over the hinge (2) and close over the lock tabs (3). 2. Install the pivot bolt (5) and tighten to 10 Nm (89 in. lbs.). 3. Reposition the storage bin/cushion cover (4). 4. Connect the zip strip (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Center Armrest / Seat Back > Page 15691 Seat Back: Service and Repair Center Seat Back Hinge Removal REMOVAL FREE PIVOT/HINGE COVER NOTE: Do not reuse the seat fasteners, always replace with new ones. 1. Remove the seat back. 2. Disconnect the storage bin/cushion cover j-strap and position aside. 3. Remove and discard the pivot bolt (1). 4. Remove the hinge spacer (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Center Armrest / Seat Back > Page 15692 5. Open the hinge cover flap (1) and remove the wire harness (5 - if equipped). 6. Remove the cover (3) from the hinge (4). INERTIA HINGE NOTE: Do not reuse the seat fasteners, always replace with new ones. 1. Remove the seat back. 2. Remove the seat back inertia hinge cover. 3. Remove and discard the inertia hinge bolts (1) and remove the hinge (3). Installation INSTALLATION FREE PIVOT HINGE/COVER Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Center Armrest / Seat Back > Page 15693 NOTE: Do not reuse the seat fasteners, always replace with new ones. 1. Position the pivot hinge cover (3) over the pivot hinge (4) and install the 12v power supply harness (5 - if equipped) into the channel. 2. Close the hinge cover (1) flat and position the spacer (2) into place. 3. Align the stop pin (3) with the spacer (2) and hinge (1) and install the assembly onto the seat back. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Center Armrest / Seat Back > Page 15694 4. Install a new pivot bolt (1) and tighten to 25 Nm (18 ft. lbs.). 5. Install the center seat back. INERTIA HINGE NOTE: Do not reuse the seat fasteners, always replace with new ones. 1. Install the inertia hinge (3) onto the center seat back (2) and install new bolts (1). 2. Tighten the bolts (1) to 25 Nm (18 ft. lbs.). 3. Install the seat back inertia hinge covers. 4. Install the center seat back. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Center Armrest / Seat Back > Page 15695 Seat Back: Service and Repair Center Seat Back Lid Removal REMOVAL 1. Open the center armrest/seat back. 2. Remove the four screws attaching the hinge to the storage bin/cushion and remove the lid. Installation INSTALLATION 1. Position the center seat back lid onto the storage bin/cushion and install the screws. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Center Armrest / Seat Back > Page 15696 Seat Back: Service and Repair Removal REMOVAL 1. Before proceeding with the following repair procedure, review all warnings and cautions. NOTE: Do not reuse the seat fasteners, always replace with new ones. 2. Remove the center seat. 3. Disconnect the storage bin/cushion cover j-straps and position aside. 4. Remove and discard the hinge bolts (2) and separate the seat back from the storage bin/cushion (1). Installation INSTALLATION 1. Before proceeding with the following repair procedure, review all warnings and cautions. NOTE: Do not reuse the seat fasteners, always replace with new ones. 2. Install the seat back onto the storage bin/cushion (1) and install new hinge bolts (2). 3. Tighten the hinge to storage bin/cushion bolts (2) to 25 Nm (18 ft. lbs.). 4. Connect the storage bin/cushion cover j-straps. 5. Install the center seat. Removal Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Center Armrest / Seat Back > Page 15697 REMOVAL NOTE: Free pivot hinge cover is removed with the free pivot hinge . 1. For the inertia hinge cover disconnect the zip strip (1). 2. Position aside the storage bin/cushion cover (4). 3. Remove the pivot bolt (5). 4. Open the hinge cover at the bottom and remove the hinge cover (1). Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Center Armrest / Seat Back > Page 15698 NOTE: Free pivot hinge cover is installed with the free pivot hinge. 1. Position the hinge cover (1) over the hinge (2) and close over the lock tabs (3). 2. Install the pivot bolt (5) and tighten to 10 Nm (89 in. lbs.). 3. Reposition the storage bin/cushion cover (4). 4. Connect the zip strip (1). Removal REMOVAL FREE PIVOT/HINGE COVER Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Center Armrest / Seat Back > Page 15699 NOTE: Do not reuse the seat fasteners, always replace with new ones. 1. Remove the seat back. 2. Disconnect the storage bin/cushion cover j-strap and position aside. 3. Remove and discard the pivot bolt (1). 4. Remove the hinge spacer (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Center Armrest / Seat Back > Page 15700 5. Open the hinge cover flap (1) and remove the wire harness (5 - if equipped). 6. Remove the cover (3) from the hinge (4). INERTIA HINGE NOTE: Do not reuse the seat fasteners, always replace with new ones. 1. Remove the seat back. 2. Remove the seat back inertia hinge cover. 3. Remove and discard the inertia hinge bolts (1) and remove the hinge (3). Installation INSTALLATION FREE PIVOT HINGE/COVER Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Center Armrest / Seat Back > Page 15701 NOTE: Do not reuse the seat fasteners, always replace with new ones. 1. Position the pivot hinge cover (3) over the pivot hinge (4) and install the 12v power supply harness (5 - if equipped) into the channel. 2. Close the hinge cover (1) flat and position the spacer (2) into place. 3. Align the stop pin (3) with the spacer (2) and hinge (1) and install the assembly onto the seat back. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Center Armrest / Seat Back > Page 15702 4. Install a new pivot bolt (1) and tighten to 25 Nm (18 ft. lbs.). 5. Install the center seat back. INERTIA HINGE NOTE: Do not reuse the seat fasteners, always replace with new ones. 1. Install the inertia hinge (3) onto the center seat back (2) and install new bolts (1). 2. Tighten the bolts (1) to 25 Nm (18 ft. lbs.). 3. Install the seat back inertia hinge covers. 4. Install the center seat back. Removal REMOVAL 1. Open the center armrest/seat back. 2. Remove the four screws attaching the hinge to the storage bin/cushion and remove the lid. Installation INSTALLATION 1. Position the center seat back lid onto the storage bin/cushion and install the screws. Removal Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Center Armrest / Seat Back > Page 15703 REMOVAL 1. Remove the front seat. 2. Remove the lumbar handle and bezel (if equipped). 3. Remove the headrest sleeves. 4. Unzip the zip strip at the lower end of the seat back and remove the seat back cover and cushion. Installation INSTALLATION 1. Install the seat back cushion and cover onto the seat frame assembly. 2. Connect the zip strip at the bottom of the seat back. 3. Install the headrest sleeves. 4. Install the lumbar bezel and handle, if equipped. 5. Install the seat. Removal REMOVAL 1. Remove the rear seat. 2. Remove the seat back bolts (1) and remove the seat back (4). Installation INSTALLATION 1. Install the seat back (4) and install the bolts (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Center Armrest / Seat Back > Page 15704 2. Tighten the bolts (1) to 25 Nm (18 ft. lbs.). 3. Install the rear seat. Removal REMOVAL 1. Remove the rear seat back. 2. Remove the headrest sleeves. 3. Unzip the zip strip at the bottom of the seat back and remove the cover. Installation INSTALLATION 1. Install the seat back cover and connect the zip strip. 2. Install the headrest sleeves. 3. Install the seat back. Removal REMOVAL 1. Remove the rear seat. 2. Remove bolts (2) and remove the loop (1). Installation INSTALLATION 1. Install the loop (1) and install the bolts (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Center Armrest / Seat Back > Page 15705 2. Tighten the bolts (2) to 12 Nm (9 ft. lbs.). 3. Install the seat. Removal REMOVAL 1. Fold both rear seats flat. 2. Remove the filler panels from the rear seat to storage compartment. 3. Separate the J-straps at the bottom of the seat back. 4. Remove both hinge covers from the back section being worked on. 5. Remove the lower anchor for the center seat belt. 6. Disconnect the lower cable attachment from the seat back release. 7. Remove the four bolts and remove the seat back from the seat. 8. Mark the location of the cables at the cushion and remove. 9. Remove the upper cushion pivot bolts. 10. Remove the lower cushion pivot bolts. 11. Remove the cushion from the seat. 12. Remove the seat release/recline handle. 13. Separate the J-straps for the cover to the seat pan. 14. Remove the cover/cushion from the seat pan and separate the foam from the cover. Installation INSTALLATION 1. Place cover over the foam and install onto the seat pan. 2. Connect the J-straps to the pan. 3. Install the release/recliner handle. 4. Install the cushion assembly onto the seat assembly. 5. Install the lower cushion pivot bolts. 6. Install the upper cushion pivot bolts. 7. Install the cables at the cushion using the marks made during removal. 8. Install the seat back onto the seat and install the four bolts. 9. Connect the lower cable attachment for the seat back release. 10. Install the lower anchor for the center seat belt. 11. Install the hinge covers. 12. Connect the J-straps at the bottom of the seat back being worked on. 13. Install the filler panels. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Fabric Cleaning/Care Seat Cover: Technical Service Bulletins Interior - Fabric Cleaning/Care NUMBER: 23-021-06 REV. A GROUP: Body DATE: August 9, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-021-06, DATED MAY 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL MODELS AND AN ADDITIONAL PART NUMBER. SUBJECT: YES Essentials(R) Stain, Odor, & Static Resistant Fabric Care MODELS: 2007 (CS) Pacifica 2007 (DR) Ram Truck **2007 (HB/HG) **2007 (JK) **2007 (JS) Avenger/Sebring ** **2007 (KA) Nitro** 2007 (MK) Compass **2007 (ND) Dakota** 2007 (PM) Caliber **2007 (PT) PT Cruiser** NOTE: This bulletin applies to vehicles equipped with YES Essentials(R) stain, odor, & static resistant fabric (sales code XGW). PARTS REQUIRED: The premium cloth upholstery in the vehicles listed is the new YES Essentials(R) stain, odor, & static resistant fabric. YES Essentials(R) fabric is an easy-care material that repels and releases soil to maintain the like-new appearance. Spills remain on the surface of the fabric to allow for easy clean up and to prevent stains and odors. The material is antimicrobial and static resistant. YES Essentials(R) fabric may be cleaned in the following manner: ^ Do NOT use any solvents or fabric protectants on Yes Essentials(R) fabric. ^ Remove as much of the stain as possible by blotting with a clean, dry towel. ^ Blot any remaining stain with a clean, damp towel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Fabric Cleaning/Care > Page 15710 ^ For tough stains, apply Mopar(R) Total Clean, p/n 04897840AA, or a mild soap solution to a clean damp cloth and remove the stain. Use a fresh, damp towel to remove the soap residue. ^ For grease stains, apply Mopar(R) Multi-purpose Cleaner, p/n 05127532AA, to a clean, damp cloth and remove the stain. Use a fresh, damp towel to remove the soap residue. CAUTION: YES Essentials(R) stain, odor, & static resistant fabric is NOT compatible with aftermarket fabric-protecting coatings. Any additional protection will damage the performance of the YES Essentials(R) stain, odor, & static resistant fabric. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Center Seat Cushion Seat Cushion: Service and Repair Center Seat Cushion Removal REMOVAL 1. Remove the center seat. 2. Remove the center armrest/seat back. Installation INSTALLATION 1. Install the center armrest/seat back. 2. Install the center seat. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Center Seat Cushion > Page 15715 Seat Cushion: Service and Repair Center Seat Cushion Cover Removal REMOVAL 1. Remove the center seat cushion or underseat storage bin lid. 2. Disconnect the zip strips and remove the cover from the cushion. Installation INSTALLATION 1. Install the cover over the center seat cushion and connect the zip strips. 2. Install the center seat cushion or under seat storage bin lid. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Center Seat Cushion > Page 15716 Seat Cushion: Service and Repair Seat Cushion / Cover - Front Removal REMOVAL 1. Remove the front seat. 2. Remove the screw and remove the recliner handle. 3. Remove the two screws and remove the power seat controls, if equipped, and disconnect the electrical connector. 4. Disconnect the j-straps and remove the seat cushion and cover. Installation INSTALLATION 1. Position the seat cushion and cover onto the frame assembly and connect the j-straps. 2. Connect the power seat control switch electrical connector, if equipped. 3. Install the power seat control switch and install the two screws, if equipped. 4. Install the recliner handle and install the screw. 5. Install the front seat. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Center Seat Cushion > Page 15717 Seat Cushion: Service and Repair Seat Cushion / Cover - Rear Removal REMOVAL 1. Remove the rear seat. 2. Separate the zip strip at the rear of the seat cushion and remove the cushion and cover. Installation INSTALLATION 1. Install the seat cushion and cover over the cushion frame assembly and connect the zip strip. 2. Install the seat. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Center Seat Cushion > Page 15718 Seat Cushion: Service and Repair Removal REMOVAL 1. Remove the center seat. 2. Remove the center armrest/seat back. Installation INSTALLATION 1. Install the center armrest/seat back. 2. Install the center seat. Removal REMOVAL 1. Remove the center seat cushion or underseat storage bin lid. 2. Disconnect the zip strips and remove the cover from the cushion. Installation INSTALLATION 1. Install the cover over the center seat cushion and connect the zip strips. 2. Install the center seat cushion or under seat storage bin lid. Removal REMOVAL 1. Remove the front seat. 2. Remove the screw and remove the recliner handle. 3. Remove the two screws and remove the power seat controls, if equipped, and disconnect the electrical connector. 4. Disconnect the j-straps and remove the seat cushion and cover. Installation INSTALLATION 1. Position the seat cushion and cover onto the frame assembly and connect the j-straps. 2. Connect the power seat control switch electrical connector, if equipped. 3. Install the power seat control switch and install the two screws, if equipped. 4. Install the recliner handle and install the screw. 5. Install the front seat. Removal REMOVAL 1. Remove the rear seat. 2. Separate the zip strip at the rear of the seat cushion and remove the cushion and cover. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Center Seat Cushion > Page 15719 1. Install the seat cushion and cover over the cushion frame assembly and connect the zip strip. 2. Install the seat. Removal REMOVAL 1. Remove the seat cushion/cover. 2. Remove the bolts (3) and remove the seat cushion frame (2). Installation INSTALLATION 1. Install the seat cushion frame (2) onto the rear seat cushion hinges (4). 2. Install the bolts (3) and tighten to 85 Nm (63 ft. lbs.). 3. Install the seat cushion/cover. Removal REMOVAL 1. Fold both rear seats flat. 2. Remove the filler panels from the rear seat to storage compartment. 3. Separate the J-straps at the bottom of the seat back. 4. Remove both hinge covers from the back section being worked on. 5. Remove the lower anchor for the center seat belt. 6. Disconnect the lower cable attachment from the seat back release. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Center Seat Cushion > Page 15720 7. Remove the four bolts and remove the seat back from the seat. 8. Remove the screw and remove the seat back release bezel. 9. Mark the location of the release cables at the cushion and remove. 10. Remove the upper cushion pivot bolts. 11. Remove the lower cushion pivot bolts. 12. Remove the cushion from the seat. 13. Remove the seat release lever from the cushion. 14. Separate the J-straps securing the cover to the seat pan. 15. Remove the foam and cover from the seat pan. 16. Separate the foam from the cover. Installation INSTALLATION 1. Position the seat cushion foam into the cover. 2. Position the cushion assembly onto the seat pan. 3. Connect the J-straps securing the cover to the seat pan. 4. Install the seat release lever. 5. Install the cushion assembly onto the seat assembly. 6. Install the lower cushion pivot bolts. 7. Install the upper cushion pivot bolts. 8. Install the release cables using the marks created during removal. 9. Install the seat back release bezel and install the screw. 10. Install the seat back and install the four bolts. 11. Connect the lower cable attachment from the seat back release. 12. Install the lower anchor fro the center seat belt. 13. Install both hinge covers for the back section seat back. 14. Connect the J-straps at the bottom of the seat back. 15. Install the filler panels for the rear storage compartment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Locations > Heater-Seat Cushion-Driver Seat Heater: Locations Heater-Seat Cushion-Driver Component ID: 141 Component : HEATER-SEAT CUSHION-DRIVER Connector: Name : HEATER-SEAT CUSHION-DRIVER Color : GREEN # of pins : 2 Pin Description Circuit 1 DRIVER SEAT HEATER SUPPLY P693 18RD/DB 2 GROUND Z939 18BK Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Locations > Heater-Seat Cushion-Driver > Page 15725 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Locations > Heater-Seat Cushion-Driver > Page 15726 Seat Heater: Locations Heater-Seat Cushion-Passenger Component ID: 142 Component : HEATER-SEAT CUSHION-PASSENGER Connector: Name : HEATER-SEAT CUSHION-PASSENGER Color : GREEN # of pins : 2 Pin Description Circuit 1 PASSENGER SEAT HEATER SUPPLY P95 16LG/WT 2 GROUND Z939 18BK Component Location - 67 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Locations > Heater-Seat Cushion-Driver > Page 15727 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Heater-Seat Cushion-Driver Seat Heater: Diagrams Heater-Seat Cushion-Driver Component ID: 141 Component : HEATER-SEAT CUSHION-DRIVER Connector: Name : HEATER-SEAT CUSHION-DRIVER Color : GREEN # of pins : 2 Pin Description Circuit 1 DRIVER SEAT HEATER SUPPLY P693 18RD/DB 2 GROUND Z939 18BK Component Location - 66 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Heater-Seat Cushion-Driver > Page 15730 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Heater-Seat Cushion-Driver > Page 15731 Seat Heater: Diagrams Heater-Seat Cushion-Passenger Component ID: 142 Component : HEATER-SEAT CUSHION-PASSENGER Connector: Name : HEATER-SEAT CUSHION-PASSENGER Color : GREEN # of pins : 2 Pin Description Circuit 1 PASSENGER SEAT HEATER SUPPLY P95 16LG/WT 2 GROUND Z939 18BK Component Location - 67 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Heater-Seat Cushion-Driver > Page 15732 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seats Seat Heater: Description and Operation Heated Seats Description DESCRIPTION WARNING: The front passenger seat assembly contains critical components that affect the front passenger airbag deployment. Correctly functioning front passenger seat components are critical for the Occupant Classification System (OCS) to properly classify the front passenger and calculate the proper airbag deployment. Unapproved modifications or service procedures to the front passenger seat assembly, its related components, or trim cover may inadvertently change the airbag deployment in case of a frontal crash. This could result in death or serious injury to the front seat passenger if the vehicle is involved in an accident. The following requirements must be strictly adhered to: - Do not modify the front passenger seat assembly or components in any way. - Do not modify the front seat center console or center position seat in any way. - Do not use prior or future model year seat trim covers not designated for the specific model being repaired. Always use the correct seat trim cover specified for the vehicle. - Do not replace the seat trim cover with an aftermarket trim cover. - Do not add a secondary trim cover other than those approved by DaimlerChrysler/Mopar. - At no time should any Supplemental Restraint System (SRS) component or SRS related component or fastener be modified or replaced with any part except those which are approved by DaimlerChrysler/Mopar. Vehicles with the heated seat option can be visually identified by the two heated seat switches located in the center stack of the instrument panel. The heated seat system allows the driver and front seat passenger to select from two different levels of electrical seat heating (HI/LO). The heated seat system for this vehicle includes the following major components: - Heated Seat Switch/Module - Two heated seat switch/modules are used per vehicle, including two Light-Emitting Diode (LED) indicator lamps for heat level indication. One switch/module for the driver and one for the passenger front seats. The switch/modules contain the solid state electronic control and diagnostic logic circuitry for the heated seat system. The switch/modules are mounted in the front center floor console. - Heated Seat Elements - Four heated seat elements are used per vehicle, one for each front seat back and one for each front seat cushion. The elements are integral to the individual front seat and seat back cushions and cannot be removed from the cushions, once installed at the factory. Operation OPERATION The heated seat system operates on battery current received through a fuse in the Totally Integrated Power Module (TIPM). Fused ignition switch output (run) circuits are used, so that the heated seat system will only operate when the ignition switch is in the On position. The heated seat system will turn Off automatically whenever the ignition switch is turned to any position except On. A Heated Seat Switch/Module is used to control the heated seat system. The switch/module responds to heated seat switch/module button input and ignition switch status inputs by controlling the 12v output to the front seat heating elements through integral solid-state relays. When either of the heated seat switch/module buttons are depressed the heating element for the selected seat is energized. Amber Light Emitting Diodes (LEDS) on the side of each switch/module indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. Pressing the switch/module button once will select high-level heating. Pressing the button a second time will select low-level heating. Pressing the button a third time will shut the heating elements off. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seats > Page 15735 The heated seat switch/module energizes an integral solid-state relay, which supplies battery current to the heating elements. When high-temperature heating is selected, the heaters provide a boosted heat level during the first four minutes of operation after heating is activated. The heat output then drops to the normal high-temperature level. If high-level heating is selected, the control system will automatically switch to the low level after two hours of continuous operation. At that time, the number of illuminated LEDs changes from two to one, indicating the change. Operation on the low setting will continue indefinitely until the switch/module button is pushed to turn the system off. The system will automatically turn off the heating elements if it detects an OPEN or LOW short in the heating element circuit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seats > Page 15736 Seat Heater: Description and Operation Heater-Seat Element Description DESCRIPTION Vehicles equipped with the optional heated seat system have two, carbon fiber heated seat elements, located in each front seat. One heating element is used for each seat cushion and another for each seat back. Each of the heated seat element consists of multiple heating circuits operating in parallel throughout the carbon fiber element. The heated seat elements are captured between the leather trim cover and the seat cushion assembly. If a malfunction occurs in one or more of the individual carbon fiber circuits, the others will continue to provide heat. The heated seat elements cannot be repaired. If found to be damaged or inoperative, a new heating element assembly must be installed. Operation OPERATION One end of the heated seat element is connected to ground at all times through a splice under the seat. Battery current is directed to the other end of the heated seat element by the heated seat switch/module. The heated seat switch/module will energize the heated seat element when the heated seat switch/module button is depressed in the Low or High position. As electrical current passes through the heated seat element, the resistance of the wire used in the element disperses some of the electrical current in the form of heat. The heat produced by the heated seat element then radiates through the underside of the seat cushion and seat back trim covers, warming the seat cover and its occupant. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Heated Seat System Seat Heater: Testing and Inspection Heated Seat System HEATED SEAT SYSTEM There are two methods of diagnosing the heated seat system. The "HEATED SEAT SYSTEM SELF-DIAGNOSIS" is to be performed when the system is inoperative and one or more of the heated seat switch/module Light Emitting Diode (LED) indicator lamps are flashing. The "HEATED SEAT SYSTEM BASE DIAGNOSIS" is to be performed when the system is inoperative and no LEDs are flashing or lighting when the switch/module buttons are pressed. HEATED SEAT SYSTEM SELF-DIAGNOSIS NOTE: Before testing the individual components in the heated seat system, check the vehicles battery open-circuit voltage and charging system performance. If the vehicles electrical system is defective or weak it may not be suppling sufficient energy to operate the heated seat system. The heated seat system is capable of performing some self-diagnostics. The following table depicts the various monitored failures which will be reported to the vehicle operator or technician by flashing the individual heated seat switch/module Light Emitting Diode (LED) indicator lamps. Refer to the Heated Seat System Self-Diagnosis table for failure identification. The driver side heated seat switch/module indicator lamps will flash if a failure occurs in the driver side heated seat, and the passenger side heated seat switch/module indicator lamps will flash for a passenger side heated seat failure. If a monitored heated seat system failure occurs, the switch/module indicator lamps will flash at a pulse rate of about one-half second on, followed by about one-half secondoff for a duration of about one minute after the switch/module for the faulty heated seat is depressed in either the Low or High direction. This process will repeat every time the faulty heated seat switch/module is actuated until the problem has been corrected. Before testing the individual components in the heated seat system, check the vehicles battery open-circuit voltage and charging system performance. If the vehicles electrical system is defective or weak it may not be suppling sufficient energy to operate the heated seat system. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Diagnostic logic is built into the heated seat switch/module to help locate the problem by the most efficient means possible. Anytime a problem is suspected, locate the diagnosis and testing procedure for the component in question and follow the steps until the specific problem is located and resolved. Once the problem is thought to be corrected, verify correct system operation. If the heated seat system is functioning correctly return the vehicle to service. If a problem could not be verified such as not finding anything wrong when following the diagnostic procedure, this is a good indication that a INTERMITTENT problem may be present. You must then attempt to find the intermittent problem, such as moving the heating element within the seat while testing continuity or wiggling the wire harness's/electrical connectors under the seat while testing continuity. Always, eliminate all other potential problems before attempting to replace the heated seat switch/module. HEATED SEAT SYSTEM BASE DIAGNOSIS NOTE: Before testing the individual components in the heated seat system, check the vehicles battery open-circuit voltage and charging system performance. If the vehicles electrical system is defective or weak it may not be suppling sufficient energy to operate the heated seat system. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. PRELIMINARY TEST Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Heated Seat System > Page 15739 - If a single LED indicator lamp for one heated seat switch/module does not operate and the heated seat elements heat, replace the switch with the inoperative indicator lamp. - If both LED indicator lamps for a heated seat switch/module operate, but the heated seat elements do not heat to check the suspect heated seat elements. If the elements test OK, proceed to STEP 1. - If both seats (driver and passenger) fail to heat and the indicator lamps on the heated seat switch/modules for both seats fail to operate, test the heated seat fuses in the Integrated Power Module (IPM). If the heated seat fuses check OK, go to STEP 1. DRIVER HEATED SEAT SWITCH/MODULE 1. Remove the heated seat switch/modules. 2. Connect the battery negative cable. 3. Turn the ignition to the "RUN" position. 4. Check for battery voltage on terminals 4 and 6 of the switch/module connector of the inoperative seat. Battery voltage should be present on both terminals. If OK go to STEP 5. If NOT OK repair the open or shorted fused B(+) circuit as required. 5. Check for continuity between ground terminal 1 of the switch/module connector of the inoperative seat and a good ground. If OK go to STEP 6. If NOT OK, repair the open or shorted ground circuit as required. 6. Check for continuity between the heated seat element supply circuit terminal 3 of the switch/module connector of the inoperative seat and the heated seat element connector of the inoperative seat. If OK go to STEP 7. If NOT OK, repair the open or shorted supply circuit as required. 7. Perform the heated seat element diagnosis for the inoperative seat. If the elements test OK, replace the inoperative heated seat switch/module. If NOT OK, replace the inoperative heated seat element. PASSENGER HEATED SEAT SWITCH/MODULE 8. Remove the heated seat switch/modules. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Heated Seat System > Page 15740 9. Connect the battery negative cable. 10. Turn the ignition to the "RUN" position. 11. Check for battery voltage on terminals 4 and 6 of the switch/module connector of the inoperative seat. Battery voltage should be present on both terminals. If OK go to STEP 5. If NOT OK repair the open or shorted fused B(+) circuit as required. 12. Check for continuity between ground terminal 1 of the switch/module connector of the inoperative seat and a good ground. If OK go to STEP 6. If NOT OK, repair the open or shorted ground circuit as required. 13. Check for continuity between the heated seat element supply circuit terminal 3 of the switch/module connector of the inoperative seat and the heated seat element connector of the inoperative seat. If OK go to STEP 7. If NOT OK, repair the open or shorted supply circuit as required. 14. Perform the heated seat element diagnosis for the inoperative seat. If the elements test OK, replace the inoperative heated seat switch/module. If NOT OK, replace the inoperative heated seat element. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Heated Seat System > Page 15741 Seat Heater: Testing and Inspection Heated Seat Element HEATED SEAT ELEMENT Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. The wire harness connectors (2&3) for the heating elements are located under the seat (1). NOTE: When checking heated seat elements for continuity, be certain to move the heating element being checked. Moving the element, such as sitting in the seat will eliminate the possibility of an intermittent open in the element which would only be evident if the element was in a certain position. Failure to check the element in various positions could result in an incomplete test. 1. Locate and disconnect the seat electrical connector. 2. Check the resistance between the circuit leading in and out of the suspect heated seat element. The resistance should be between 3.8 - 4.8 ohms for a seat cushion element and 4.3 - 5.4 ohms for a seat back element. If OK, refer to Heated Seats. If not OK, replace the inoperative heated seat element. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Removal Seat Heater: Service and Repair Removal REMOVAL NOTE: Do not remove the factory installed heating elements (3) from the seat or seat back cushions. The original element is permanently attached and cannot be removed without permanent damage. The replacement heating element is designed to be applied directly on top of the inoperative factory installed heating element. 1. Disconnect and isolate the negative battery cable. 2. Remove the appropriate seat cushion or seat back trim cover. 3. Disconnect the inoperative heated seat cushion or seat back element electrical connectors (2). 4. Locate the wires leading from the inoperative heating element and cut them off flush with the edge of the original heating element. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Removal > Page 15744 Seat Heater: Service and Repair Installation INSTALLATION 1. Peel off the adhesive backing on the back of the replacement heating element (2) and stick directly on top of the factory installed heating element (1). CAUTION: During the installation of the replacement heating element, be careful not to fold or crease the element assembly. Folds or creases will cause premature failure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Removal > Page 15745 ERROR: undefined OFFENDING COMMAND: ‘~ STACK: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Description and Operation > Description Seat Heater Control Module: Description and Operation Description DESCRIPTION Momentary contact push button switch/modules mounted in the instrument panel center bezel operate the heated seat system. Each heated seat switch/module has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected level (Low or High) of the seat heater. Pressing the switch/module button initiates heat. Heat remains on until switched off or until the ignition is turned off. If switched off by the ignition, a switch/module button must be pressed to restart heating. The switch/modules contain the solid state electronic control and diagnostic logic circuitry for the heated seat system. If any of the heated seat elements are inoperative or damaged one or more of the LED lamps in the switch/module for the effected seat will flash. The LED indicator lamps in each heated seat switch/module cannot be repaired. If the LED lamps are faulty or damaged, or the switch/module is inoperative or damaged the individual heated seat switch/module assembly must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Description and Operation > Description > Page 15750 Seat Heater Control Module: Description and Operation Operation OPERATION A Heated Seat Switch/Module is used to control the heated seat system. The heated seat switch/modules receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The switch/module responds to heated seat switch/module button input and ignition switch status inputs by controlling the 12v output to the front seat heating elements through integral solid-state relays. When either of the heated seat switch/module buttons are depressed the heating element for the selected seat is energized. Amber Light Emitting Diodes (LEDS) on the side of each switch/module indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. Pressing the switch/module button once will select high-level heating. Pressing the button a second time will select low-level heating. Pressing the button a third time will shut the heating elements off. The heated seat switch/module energizes an integral solid-state relay, which supplies battery current to the heating elements. When high-temperature heating is selected, the heaters provide a boosted heat level during the first four minutes of operation after heating is activated. The heat output then drops to the normal high-temperature level. If high-level heating is selected, the control system will automatically switch to the low level after two hours of continuous operation. At that time, the number of illuminated LEDs changes from two to one, indicating the change. Operation on the low setting will continue indefinitely until the switch/module button is pushed to turn the system off. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Removal Seat Heater Control Module: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. 3. Disconnect the switch/module electrical connectors. 4. Using an appropriate flat bladed tool, remove the heated seat switch/module from the bezel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Removal > Page 15753 Seat Heater Control Module: Service and Repair Installation INSTALLATION 1. Align the tabs of the switch/module to the instrument panel center bezel and gently push together until the tabs are securely in place. 2. Connect the switch/module electrical connectors. 3. Install the instrument panel center bezel. 4. Connect the battery negative cable. 5. Verify heated seat system operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver Seat Heater Switch: Locations Switch-Heated Seat-Driver Component ID: 467 Component : SWITCH-HEATED SEAT-DRIVER Connector: Name : SWITCH-HEATED SEAT-DRIVER Color : DK. GRAY # of pins : 6 Pin Description Circuit 1 GROUND Z301 20TN/BK 2 PANEL LAMPS DRIVER P301 20LG/OR 3 DRIVER SEAT HEATER SUPPLY P693 18LG/WT 4 FUSED B(+) A930 16RD 5-6 FUSED B(+) A930 16RD Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver > Page 15758 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver > Page 15759 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver > Page 15760 Seat Heater Switch: Locations Switch-Heated Seat-Passenger Component ID: 468 Component : SWITCH-HEATED SEAT-PASSENGER Connector: Name : SWITCH-HEATED SEAT-PASSENGER Color : GREEN # of pins : 6 Pin Description Circuit 1 GROUND Z302 20LG/BK 2 PANEL LAMPS DRIVER P301 20LG/OR 3 PASSENGER SEAT HEATER SUPPLY P95 18LG/WT 4 FUSED B(+) A930 16RD 5-6 FUSED B(+) A930 16RD Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver > Page 15761 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver > Page 15762 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver Seat Heater Switch: Diagrams Switch-Heated Seat-Driver Component ID: 467 Component : SWITCH-HEATED SEAT-DRIVER Connector: Name : SWITCH-HEATED SEAT-DRIVER Color : DK. GRAY # of pins : 6 Pin Description Circuit 1 GROUND Z301 20TN/BK 2 PANEL LAMPS DRIVER P301 20LG/OR 3 DRIVER SEAT HEATER SUPPLY P693 18LG/WT 4 FUSED B(+) A930 16RD 5-6 FUSED B(+) A930 16RD Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver > Page 15765 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver > Page 15766 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver > Page 15767 Seat Heater Switch: Diagrams Switch-Heated Seat-Passenger Component ID: 468 Component : SWITCH-HEATED SEAT-PASSENGER Connector: Name : SWITCH-HEATED SEAT-PASSENGER Color : GREEN # of pins : 6 Pin Description Circuit 1 GROUND Z302 20LG/BK 2 PANEL LAMPS DRIVER P301 20LG/OR 3 PASSENGER SEAT HEATER SUPPLY P95 18LG/WT 4 FUSED B(+) A930 16RD 5-6 FUSED B(+) A930 16RD Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver > Page 15768 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver > Page 15769 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation > Description Seat Heater Switch: Description and Operation Description DESCRIPTION Momentary contact push button switch/modules mounted in the instrument panel center bezel operate the heated seat system. Each heated seat switch/module has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected level (Low or High) of the seat heater. Pressing the switch/module button initiates heat. Heat remains on until switched off or until the ignition is turned off. If switched off by the ignition, a switch/module button must be pressed to restart heating. The switch/modules contain the solid state electronic control and diagnostic logic circuitry for the heated seat system. If any of the heated seat elements are inoperative or damaged one or more of the LED lamps in the switch/module for the effected seat will flash. The LED indicator lamps in each heated seat switch/module cannot be repaired. If the LED lamps are faulty or damaged, or the switch/module is inoperative or damaged the individual heated seat switch/module assembly must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation > Description > Page 15772 Seat Heater Switch: Description and Operation Operation OPERATION A Heated Seat Switch/Module is used to control the heated seat system. The heated seat switch/modules receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The switch/module responds to heated seat switch/module button input and ignition switch status inputs by controlling the 12v output to the front seat heating elements through integral solid-state relays. When either of the heated seat switch/module buttons are depressed the heating element for the selected seat is energized. Amber Light Emitting Diodes (LEDS) on the side of each switch/module indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. Pressing the switch/module button once will select high-level heating. Pressing the button a second time will select low-level heating. Pressing the button a third time will shut the heating elements off. The heated seat switch/module energizes an integral solid-state relay, which supplies battery current to the heating elements. When high-temperature heating is selected, the heaters provide a boosted heat level during the first four minutes of operation after heating is activated. The heat output then drops to the normal high-temperature level. If high-level heating is selected, the control system will automatically switch to the low level after two hours of continuous operation. At that time, the number of illuminated LEDs changes from two to one, indicating the change. Operation on the low setting will continue indefinitely until the switch/module button is pushed to turn the system off. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Removal Seat Heater Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. 3. Disconnect the switch/module electrical connectors. 4. Using an appropriate flat bladed tool, remove the heated seat switch/module from the bezel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Removal > Page 15775 Seat Heater Switch: Service and Repair Installation INSTALLATION 1. Align the tabs of the switch/module to the instrument panel center bezel and gently push together until the tabs are securely in place. 2. Connect the switch/module electrical connectors. 3. Install the instrument panel center bezel. 4. Connect the battery negative cable. 5. Verify heated seat system operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Description and Operation > Description Seat Track: Description and Operation Description DESCRIPTION The eight-way power seat option includes a power seat track assembly (1) located under each front seat. The power seat track assembly replaces the standard manually operated seat tracks. The lower half of the power seat track is secured at the front with two bolts to the floor panel seat cross member, and at the rear with two bolts to the floor panel. Four nuts secure the bottom of the seat cushion frame to the upper half of the power seat track unit. The power seat track assembly cannot be repaired, and is serviced only as a complete assembly. If any component in this assembly is inoperative or damaged, the entire power seat track must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Description and Operation > Description > Page 15780 Seat Track: Description and Operation Operation OPERATION The power seat track unit includes three reversible electric motors that are secured to the upper half of the track unit. Each motor moves the seat adjuster through a combination of worm-drive gearboxes and screw-type drive units. The front and rear of the seat are operated by two separate vertical adjustment motors. These motors can be operated independently of each other, tilting the entire seat assembly forward or rearward; or, they can be operated in unison by selecting the proper power seat switch functions, which will raise or lower the entire seat assembly. The third motor is the horizontal adjustment motor, which moves the seat track in the forward and rearward directions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Description and Operation > Page 15781 Seat Track: Testing and Inspection POWER SEAT TRACK For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Operate the power seat switch to move all three seat motors in each direction. The seat should move in each of the selected directions. If the power seat track fails to operate in only one direction, move the seat track a short distance in the opposite direction and test again to be certain that the track is not at its travel limit. If the power seat track still fails to operate in only one direction. If the power seat track fails to operate in more than one direction, proceed as follows: 1. Check the power seat fuse in the integrated power module. If OK, go to STEP 2. If not OK, repair the circuit as necessary and replace the inoperative fuse. 2. Remove the power seat switch from the seat. Check for battery voltage at the fused B(+) circuit cavity of the power seat switch wire harness connector. If OK, go to STEP 3. If not OK, repair the open circuit to the integrated power module as required. 3. Check for continuity between the ground circuit cavity of the power seat switch wire harness connector and a good ground. There should be continuity. If OK, go to STEP 4. If not OK, repair the open circuit to ground as required. 4. Test the power seat switch. If the switch tests OK, check the wire harness between the power seat switch and the motor for shorts or opens. If the circuits check OK, replace the inoperative power seat track (adjuster) assembly. If the circuits are not OK, repair the wire harness as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Removal Seat Track: Service and Repair Removal REMOVAL 1. Remove the appropriate seat from the vehicle. 2. Remove the power seat switch from the seat. 3. Remove four seat track mounting nuts from cushion pan. 4. Disconnect the power seat electrical connectors and remove the seat track from the seat cushion. 5. Remove the necessary components that must be transferred to the replacement seat track (seat belt buckles, wire harness, etc.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Removal > Page 15784 Seat Track: Service and Repair Installation INSTALLATION 1. Install the necessary components that must be transferred to the replacement seat track (seat belt buckles, wire harness, etc.). 2. Position the seat track and install the retaining nuts on the seat cushion pan studs. Torque the bolts to 25 Nm. 3. Route and connect the power seat electrical connectors on the seat track and cushion pan. 4. Install the power seat switch on the seat. 5. Install the seat in the vehicle. 6. Connect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Customer Interest for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood Hood Sensor/Switch (For Alarm): Customer Interest Antitheft System - Goes Off When Opening The Hood NUMBER: 08-040-06 GROUP: Electrical DATE: September 06, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: Vehicle Theft Security System Alarm May Alert When Hood Is Opened OVERVIEW: This bulletin involves selectively erasing and reprogramming the Cabin Compartment Node Module (CCN) with new software. MODELS: 2007 (DR/DH/D1/DC) Ram Truck NOTE: This bulletin applies to vehicles equipped with a remote start system (sales code XBM) prior to October 10, 2006 (MDH 1010XX). SYMPTOM/CONDITION: The Vehicle Theft Security System (VTSS) may alert (flash lights and/or sound horn) if one of the following occurs: a. The customer arms the VTSS and then reaches through an open window, pulls on the hood release, and fully opens the vehicle hood. b. The customer releases the hood but not enough to open the hood ajar switch, arms the VTSS, and then fully opens the vehicle hood. c. The customer opens the hood, arms the VTSS, the vehicle communications bus goes in to "sleep mode" (may take 10 minutes), then the "LOCK" button on the key fob is depressed. The hood ajar switch is not part of the VTSS used on domestic use vehicles. The hood ajar switch is used for export vehicles equipped with the Vehicle Theft Alarm (VTA) system. DIAGNOSIS: 1. Connect the StarSCAN(R) to the vehicle. 2. Power up the StarSCAN(R) and obtain the HOME menu. 3. From the HOME menu select "ECU VIEW". 4. Select "CCN - Cabin Compartment". 5. Select "More Options". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Customer Interest for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 15795 6. Select "ECU Flash" 7. Read and record the software part number that is display with "Resident Flash File For Part". 8. Is the software part number 05172187AC (or later)? a. If YES >>> then STOP. This bulletin does not apply. Further diagnosis is required. b. If NO >>> then perform the Repair Procedure. NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the CCN in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash CCN" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Customer Interest for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 15796 13. Highlight the listed calibration. 14. Select "Update Controller". Follow on screen instructions. 15. When the CCN update is complete, select "OK". 16. Verify the part number at the top of the "Flash CCN" screen has updated to the new part number. NOTE: Due to the CCN programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood Hood Sensor/Switch (For Alarm): All Technical Service Bulletins Antitheft System - Goes Off When Opening The Hood NUMBER: 08-040-06 GROUP: Electrical DATE: September 06, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: Vehicle Theft Security System Alarm May Alert When Hood Is Opened OVERVIEW: This bulletin involves selectively erasing and reprogramming the Cabin Compartment Node Module (CCN) with new software. MODELS: 2007 (DR/DH/D1/DC) Ram Truck NOTE: This bulletin applies to vehicles equipped with a remote start system (sales code XBM) prior to October 10, 2006 (MDH 1010XX). SYMPTOM/CONDITION: The Vehicle Theft Security System (VTSS) may alert (flash lights and/or sound horn) if one of the following occurs: a. The customer arms the VTSS and then reaches through an open window, pulls on the hood release, and fully opens the vehicle hood. b. The customer releases the hood but not enough to open the hood ajar switch, arms the VTSS, and then fully opens the vehicle hood. c. The customer opens the hood, arms the VTSS, the vehicle communications bus goes in to "sleep mode" (may take 10 minutes), then the "LOCK" button on the key fob is depressed. The hood ajar switch is not part of the VTSS used on domestic use vehicles. The hood ajar switch is used for export vehicles equipped with the Vehicle Theft Alarm (VTA) system. DIAGNOSIS: 1. Connect the StarSCAN(R) to the vehicle. 2. Power up the StarSCAN(R) and obtain the HOME menu. 3. From the HOME menu select "ECU VIEW". 4. Select "CCN - Cabin Compartment". 5. Select "More Options". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 15802 6. Select "ECU Flash" 7. Read and record the software part number that is display with "Resident Flash File For Part". 8. Is the software part number 05172187AC (or later)? a. If YES >>> then STOP. This bulletin does not apply. Further diagnosis is required. b. If NO >>> then perform the Repair Procedure. NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the CCN in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash CCN" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Sensor/Switch (For Alarm): > 08-040-06 > Sep > 06 > Antitheft System - Goes Off When Opening The Hood > Page 15803 13. Highlight the listed calibration. 14. Select "Update Controller". Follow on screen instructions. 15. When the CCN update is complete, select "OK". 16. Verify the part number at the top of the "Flash CCN" screen has updated to the new part number. NOTE: Due to the CCN programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 15804 Hood Sensor/Switch (For Alarm): Locations Component ID: 469 Component : SWITCH-HOOD AJAR Connector: Name : SWITCH-HOOD AJAR Color : # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 HOOD AJAR SWITCH SENSE G70 20VT/LB 2 AAT RETURN G930 20VT/TN Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 15805 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 15806 Hood Sensor/Switch (For Alarm): Diagrams Component ID: 469 Component : SWITCH-HOOD AJAR Connector: Name : SWITCH-HOOD AJAR Color : # of pins : 2 Qualifier : (GAS) Pin Description Circuit 1 HOOD AJAR SWITCH SENSE G70 20VT/LB 2 AAT RETURN G930 20VT/TN Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Technical Service Bulletins > Page 15807 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Description Hood Sensor/Switch (For Alarm): Description and Operation Description DESCRIPTION The hood ajar switch is a normally closed, single pole, spring-loaded plunger actuated switch. This switch has two unique versions that are used in two different applications. One switch is used only on vehicles equipped with the Vehicle Theft Alarm (VTA) system for sale in certain export markets where protection of the underhood area is required equipment. The second switch is used only on domestic vehicles equipped with an optional remote starter system. The molded plastic switch body (5) has an integral molded connector receptacle (1) on the lower end containing two terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the headlamp and dash wire harness. Two integral latches (2) lock the switch into a keyed mounting hole in the stamped steel switch mounting bracket. The mounting bracket is secured with screws to the inboard side of the right front fender load beam within the engine compartment. A molded plastic striker secured to the underside of the hood panel inner reinforcement actuates the switch plunger as the hood panel is closed. The switch plunger (3) extends through a mounting collar (4) and a sleeve-like retainer ring on the upper end of the switch body. The retainer ring has a one time, self-adjustment feature that is activated after the switch is installed by closing the hood. The retainer ring is also color-coded to aid in identifying the switch application. A dark brown retainer ring identifies the underhood security switch application, while a white retainer ring identifies the remote starter system application. An installed hood ajar switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or requires readjustment, it must be replaced with a new unit. The hood ajar switch striker is not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced with a new unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Description > Page 15810 Hood Sensor/Switch (For Alarm): Description and Operation Operation OPERATION The hood ajar switches are interchangeable physically, but not functionally. In each case, the hood ajar switch is a normally closed switch that is held open as the spring-loaded switch plunger is depressed by the striker on the inner hood panel reinforcement when the hood panel is closed and latched. When the hood is opened, the spring-loaded switch plunger extends from the switch body and the switch contacts are closed. In the underhood security application (export vehicles only - dark brown retainer ring), the switch is connected in series between ground and the hood ajar switch sense input of the Totally Integrated Power Module (TIPM). The TIPM uses an internal resistor pull up to monitor the state of the hood ajar switch contacts. In the remote starter system application (domestic vehicles only - white retainer ring) the switch has a 1 kilo ohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between an output of the TIPM and the hood ajar switch sense input of the TIPM. The TIPM continually monitors this circuit and will store a Diagnostic Trouble Code (DTC) for any fault that it detects. The components of the switch self-adjustment feature include an integral stop on the shaft of the plunger and a ribbed, ratcheting sleeve-like retainer ring at the top of the switch body from which the plunger extends. With the switch mounting collar secured in its mounting bracket, the plunger is depressed by the striker on the hood inner reinforcement as the hood is closed. As the plunger is depressed, the plunger stop contacts the top of the retainer ring and it is driven downward, ratcheting through the switch mounting collar until the hood is fully closed and latched. The ribs on the retainer ring are engaged within the mounting collar to maintain this adjusted position. The hood ajar switch as well as the hard wired circuits between the switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between modules and other devices related to hood ajar switch operation that provide some features of the export vehicle theft or domestic remote starter systems. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to hood ajar switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal Hood Sensor/Switch (For Alarm): Service and Repair Removal Striker STRIKER NOTE: The hood ajar switch striker is not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Unlatch and open the hood. 2. Using a trim stick or another suitable wide flat-bladed tool, pry the rearward end of the hood ajar switch striker (2) away from the inner hood panel reinforcement (1) far enough to disengage the integral retainers from their mounting holes. 3. Remove the striker from the inner hood panel reinforcement and discard. Bracket BRACKET 1. Remove the hood ajar switch (2) from the mounting bracket (3). 2. Remove the two screws (4) that secure the hood ajar switch bracket to the two rivet nuts (1) in the right front load beam (6). 3. Remove the hood ajar switch mounting bracket from the inboard side of the right front load beam. Switch SWITCH Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal > Page 15813 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. From the top of the mounting bracket (3) on the right front load beam (6), squeeze the two hood ajar switch (2) latch tabs together and pull the switch upward. 4. Pull the hood ajar switch up through the hole in the mounting bracket far enough to access and disconnect the jumper wire harness connector (5) from the switch connector receptacle. 5. Remove the hood ajar switch from the mounting bracket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal > Page 15814 Hood Sensor/Switch (For Alarm): Service and Repair Installation Striker STRIKER NOTE: The hood ajar switch striker cap is not intended for reuse. If the striker cap is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Position the new hood ajar switch striker (2) to the mounting holes in the inner hood panel reinforcement (1) over the hood ajar switch (3). 2. Using hand pressure, press the hood ajar switch striker upward into the mounting holes in the inner hood panel reinforcement until both integral retainers are fully engaged. 3. Close and latch the hood. Bracket BRACKET 1. Check to be certain that the two rivet nuts (1) on the inboard side of the right front load beam (6) are in good condition and properly secured. 2. Position the hood ajar switch mounting bracket (3) onto the right front load beam. 3. Install and tighten the two screws (4) that secure the mounting bracket to the load beam. Beginning with the rearward screw, tighten both screws to 8 Nm (71 in. lbs.). 4. Reinstall the hood ajar switch (2) into the mounting bracket. Switch Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal > Page 15815 SWITCH 1. Position the hood ajar switch (2) near the hole in the mounting bracket (3) on the right front load beam (6). 2. Route the jumper wire harness connector (5) through the switch mounting bracket and reconnect it to the switch connector receptacle. 3. From the top of the mounting bracket, press the switch downward into the mounting hole until the integral switch latch tabs lock it into place. 4. Reconnect the battery negative cable. 5. Close and latch the hood. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Component ID: 457 Component : SWITCH-ADJUSTABLE PEDALS Connector: Name : SWITCH-ADJUSTABLE PEDALS Color : BLUE # of pins : 6 Qualifier : (EXCEPT BASE) Pin Description Circuit 1 ADJUSTABLE PEDALS MOTOR REARWARDP206 18LG/LB 2 ADJUSTABLE PEDALS OUTPUT A72 18RD/OR 3-4 GROUND Z146 18BK 5 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 6 ADJUSTABLE PEDALS MOTOR FORWARD P205 18LG/WT Component Location - 44 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 15819 Component Location - 50 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 15820 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 15821 Pedal Positioning Switch: Diagrams Component ID: 457 Component : SWITCH-ADJUSTABLE PEDALS Connector: Name : SWITCH-ADJUSTABLE PEDALS Color : BLUE # of pins : 6 Qualifier : (EXCEPT BASE) Pin Description Circuit 1 ADJUSTABLE PEDALS MOTOR REARWARDP206 18LG/LB 2 ADJUSTABLE PEDALS OUTPUT A72 18RD/OR 3-4 GROUND Z146 18BK 5 FUSED IGNITION SWITCH OUTPUT (RUN) F504 20GY/PK 6 ADJUSTABLE PEDALS MOTOR FORWARD P205 18LG/WT Component Location - 44 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 15822 Component Location - 50 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 15823 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Service and Repair > Removal Pedal Positioning Switch: Service and Repair Removal REMOVAL 1. Remove the lower drivers side bezel (4). 2. Disconnect the electrical connector (3) from the adjustable pedal switch (2). 3. Remove the switch (2) from the lower drivers side bezel (4) by squeezing the retaining clips together and pushing the switch outwards. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Service and Repair > Removal > Page 15826 Pedal Positioning Switch: Service and Repair Installation INSTALLATION 1. Install the switch (2) to the lower drivers side bezel (4) by pushing the switch inwards seating the retaining clips to the lower drivers side bezel (4). 2. Reconnect the electrical connector (3) to the adjustable pedal switch (2). 3. Install the lower drivers side bezel (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Switch-Door Lock-Passenger Power Door Lock Switch: Locations Switch-Door Lock-Passenger Component ID: 462 Component : SWITCH-DOOR LOCK-PASSENGER Connector: Name : SWITCH-DOOR LOCK-PASSENGER Color : NATURAL # of pins : 6 Pin Description Circuit 1 PASSENGER DOOR LOCK SWITCH MUX G160 20VT/LG 2 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 3-4-5 GROUND Z917 20BK 6-Component Location - 56 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Switch-Door Lock-Passenger > Page 15831 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Switch-Door Lock-Passenger > Page 15832 Power Door Lock Switch: Locations Switch-Window/Door Lock-Driver Component ID: 494 Component : SWITCH-WINDOW/DOOR LOCK-DRIVER Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C1 Color : BLUE # of pins : 12 Pin Description Circuit 1 RIGHT REAR WINDOW DRIVER (DOWN) Q612 14OR/DB 2 RIGHT REAR WINDOW DRIVER (UP) Q412 14OR/LB 3 MASTER WINDOW SWITCH RIGHT FRONT (UP) Q16 12OR/TN 4 LEFT REAR WINDOW DRIVER (UP) Q411 14OR/WT 5 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 6 MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Q26 12OR/GY 7 DRIVER DOOR LOCK SWITCH MUX G161 20VT/DG 8 GROUND Z939 12BK 9 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 12PK/YL 10 LEFT REAR WINDOW DRIVER (DOWN) Q611 14OR/GY 11 GROUND Z939 18BK 12 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Switch-Door Lock-Passenger > Page 15833 Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C2 Color : BLUE # of pins : 8 Pin Description Circuit 1 LEFT MIRROR UP DRIVER P71 20TN/DG 2 LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) P195 18LG/YL 3 FUSED B(+) A940 18RD 4 RIGHT MIRROR LEFT DRIVER P74 18TN/OR 5 GROUND Z939 18BK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Switch-Door Lock-Passenger > Page 15834 6 LEFT MIRROR LEFT DRIVER P75 20TN/LG 7 RIGHT MIRROR UP DRIVER P72 18TN/GY 8 POWER WINDOW SWITCH FEED Q15 12OR/LB Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger Power Door Lock Switch: Diagrams Switch-Door Lock-Passenger Component ID: 462 Component : SWITCH-DOOR LOCK-PASSENGER Connector: Name : SWITCH-DOOR LOCK-PASSENGER Color : NATURAL # of pins : 6 Pin Description Circuit 1 PASSENGER DOOR LOCK SWITCH MUX G160 20VT/LG 2 FUSED IGNITION SWITCH OUTPUT (RUN-START) F21 20PK/DG 3-4-5 GROUND Z917 20BK 6-Component Location - 56 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger > Page 15837 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger > Page 15838 Power Door Lock Switch: Diagrams Switch-Window/Door Lock-Driver Component ID: 494 Component : SWITCH-WINDOW/DOOR LOCK-DRIVER Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C1 Color : BLUE # of pins : 12 Pin Description Circuit 1 RIGHT REAR WINDOW DRIVER (DOWN) Q612 14OR/DB 2 RIGHT REAR WINDOW DRIVER (UP) Q412 14OR/LB 3 MASTER WINDOW SWITCH RIGHT FRONT (UP) Q16 12OR/TN 4 LEFT REAR WINDOW DRIVER (UP) Q411 14OR/WT 5 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 6 MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Q26 12OR/GY 7 DRIVER DOOR LOCK SWITCH MUX G161 20VT/DG 8 GROUND Z939 12BK 9 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 12PK/YL 10 LEFT REAR WINDOW DRIVER (DOWN) Q611 14OR/GY 11 GROUND Z939 18BK 12 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger > Page 15839 Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C2 Color : BLUE # of pins : 8 Pin Description Circuit 1 LEFT MIRROR UP DRIVER P71 20TN/DG 2 LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) P195 18LG/YL 3 FUSED B(+) A940 18RD 4 RIGHT MIRROR LEFT DRIVER P74 18TN/OR 5 GROUND Z939 18BK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger > Page 15840 6 LEFT MIRROR LEFT DRIVER P75 20TN/LG 7 RIGHT MIRROR UP DRIVER P72 18TN/GY 8 POWER WINDOW SWITCH FEED Q15 12OR/LB Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Description Power Door Lock Switch: Description and Operation Description DESCRIPTION A window/lock switch is used on all models equipped with power locks, power windows, and power mirrors. The window/lock switch houses the following switches: - Power Lock Switch - A two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Mirror Selector Switch - A three-position rocker switch selects the right or left power mirror for adjustment, or turns the power mirror system Off. - Power Mirror Adjustment Switches - Four momentary, arrowhead shaped, directional switches allow the driver to adjust the selected power mirror in the Up, Down, Right, or Left directions. - Power Window Lockout Switch - A two-way, latching, push-button switch allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches. - Power Window Switches - A two-way, momentary power window switch for the driver side front door. This switch also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, there are individual master switches for each passenger door power window. The window/lock switch also incorporates several green Light-Emitting Diodes (LEDs) that illuminate the power lock and power window switch paddles, and the power mirror switch directional buttons to improve switch visibility. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Description > Page 15843 Power Door Lock Switch: Description and Operation Operation OPERATION The window/lock switch combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single unit. Power Lock Switch The power lock switch circuitry is connected in series between ground and the driver door switch mux input of the instrument cluster. Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the instrument cluster input, which allows the instrument cluster to sense the switch position. Based upon the power lock switch input, the instrument cluster controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door latches. The Light-Emitting Diode (LED) in the power lock switch is connected to battery current through the power window circuit breaker in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run-acc) circuit. The switch will be illuminated whenever the ignition switch is in the On or Accessory positions. Power Window Switches The power window switch circuitry is connected to battery current through a circuit breaker in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run-acc) circuit so that the power windows will operate whenever the ignition switch is in the On or Accessory positions. Each two-way, momentary master passenger power window switch provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The switch for the driver side front door power window is labeled "Auto" and includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the master switches. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Power Mirror Switches The power mirror switch circuitry is connected to battery current through a fuse in the TIPM on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one to select the left mirror, and a neutral Off position. After the right or left mirror is selected, one of four directional buttons is depressed to move the selected mirror Up, Down, Right or Left. The power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the power mirror switch is connected to battery current through the power window circuit breaker in the TIPM on a fused ignition switch output (run-acc) circuit so that the switch directional buttons will be illuminated whenever the ignition switch is in the On or Accessory positions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Power Lock Switch Power Door Lock Switch: Testing and Inspection Power Lock Switch POWER LOCK SWITCH The Light-Emitting Diode (LED) illumination lamp of the power lock switch receives battery current through a fuse in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run) circuit. The power lock switch on the driver side front door trim panel is integral to the window/lock switch. If the power lock switch operates, but the LED is inoperative, check for battery current at the switch with the ignition switch in the On position. If OK, replace the faulty switch. Refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. Remove the power lock switch from the door trim panel. Disconnect the door wire harness connector for the power lock switch from the switch connector receptacle. 2. Test the power lock switch resistance. See the Power Lock Switch Test chart to determine if the resistance is correct for the switch in each switch position. If not OK, replace the faulty power lock switch as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Power Lock Switch > Page 15846 Power Door Lock Switch: Testing and Inspection Window/Lock Switch WINDOW/LOCK SWITCH The Light-Emitting Diode (LED) illumination lamps for all of the Driver Door Module (DDM) power window, power lock, and power mirror switches receive battery current through the power window circuit breaker in the Totally Integrated Power Module (TIPM). If all of the LED's are inoperative in the DDM, be certain to diagnose the power window system before replacing the switch unit. If only one LED in the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty DDM. Refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles. 2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position. If not OK, replace the faulty DDM as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Power Lock Switch > Page 15847 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Power Lock Switch > Page 15848 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Removal Power Door Lock Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Removal > Page 15851 Power Door Lock Switch: Service and Repair Installation INSTALLATION 1. Install switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair Power Mirror Switch: Service and Repair REMOVAL The power mirror switch is included with the window/lock switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Switch-Seat-Driver Power Seat Switch: Diagrams Switch-Seat-Driver Component ID: 484 Component : SWITCH-SEAT-DRIVER Connector: Name : SWITCH-SEAT-DRIVER Color : # of pins : 12 Qualifier : (HD) A FUSED B(+) A210 12OR/RD B GROUND Z939 14BK C-E DRIVER SEAT REAR UP DRIVER P11 12LG/YL F-G GROUND Z939 14BK H FUSED B(+) A210 12OR/RD J DRIVER SEAT REAR DOWN DRIVER P13 12LG/OR K DRIVER SEAT HORIZONTAL REARWARD DRIVER P17 12LG/DG L DRIVER SEAT HORIZONTAL FORWARD DRIVER P15 12LG/BR M DRIVER SEAT FRONT UP DRIVER P19 12LG/LB N DRIVER SEAT FRONT DOWN DRIVER P21 12LG/TN Connector: Name : SWITCH-SEAT-DRIVER Color : GRAY # of pins : 8 Qualifier : (LD) Gender : MALE Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Switch-Seat-Driver > Page 15859 Pin Description Circuit 1 DRIVER SEAT FRONT UP DRIVER P19 12LG/LB 2 GROUND Z939 14BK 3 DRIVER SEAT HORIZONTAL FORWARD DRIVER P15 12LG/WT 4 FUSED B(+) A210 12OR/RD 5 DRIVER SEAT REAR UP DRIVER P11 12LG/YL 6 DRIVER SEAT HORIZONTAL REARWARD DRIVER P17 12LG/DG 7 DRIVER SEAT REAR DOWN DRIVER P13 12LG/OR 8 DRIVER SEAT FRONT DOWN DRIVER P21 12LG/TN Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Switch-Seat-Driver > Page 15860 Power Seat Switch: Diagrams Switch-Seat-Passenger Component ID: 485 Component : SWITCH-SEAT-PASSENGER Connector: Name : SWITCH-SEAT-PASSENGER Color : # of pins : 12 A FUSED B(+) A210 12OR/RD B GROUND Z939 14BK C-E PASSENGER SEAT REAR UP DRIVER P12 12LG/YL F-G GROUND Z939 14BK H FUSED B(+) A210 12OR/RD J PASSENGER SEAT REAR DOWN DRIVER P10 12LG/TN K PASSENGER SEAT HORIZONTAL REARWARD DRIVER P16 12LG/BR L PASSENGER SEAT HORIZONTAL FORWARD DRIVER P14 12LG/OR M PASSENGER SEAT FRONT UP DRIVER P20 12LG/LB N PASSENGER SEAT FRONT DOWN DRIVER P18 12LG/OR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Description Power Seat Switch: Description and Operation Description DESCRIPTION The power seats on this vehicle can be adjusted in eight different directions, up, down, front up, front down, rear up, rear down, rearward and forward. The power seat switch is located on the outboard side of the seat cushion on the seat cushion side shield. The individual switches in the power seat switch assembly cannot be repaired. If one switch is damaged or inoperative, the entire power seat switch assembly must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Description > Page 15863 Power Seat Switch: Description and Operation Operation OPERATION When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Page 15864 Power Seat Switch: Testing and Inspection POWER SEAT SWITCH For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. 3. Using an ohmmeter to test the continuity of the power seat switches in each position. If OK Refer to Power Seat Track Testing. If not OK, replace the inoperative power seat switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Removal Power Seat Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side shield from the seat. 3. Pull the switch bezel or side shield unit (1) out from the seat far enough to access the switch wire harness connector. Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module (2). 4. Remove the screws (3) that secure the power seat switch (2) to the side shield unit (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Removal > Page 15867 Power Seat Switch: Service and Repair Installation INSTALLATION 1. Position the power seat switch (2) on the seat cushion side shield (1) and install the screws (3). 2. Connect the electrical connector. 3. Install the seat cushion side shield on the seat. 4. Connect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver Seat Heater Switch: Locations Switch-Heated Seat-Driver Component ID: 467 Component : SWITCH-HEATED SEAT-DRIVER Connector: Name : SWITCH-HEATED SEAT-DRIVER Color : DK. GRAY # of pins : 6 Pin Description Circuit 1 GROUND Z301 20TN/BK 2 PANEL LAMPS DRIVER P301 20LG/OR 3 DRIVER SEAT HEATER SUPPLY P693 18LG/WT 4 FUSED B(+) A930 16RD 5-6 FUSED B(+) A930 16RD Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver > Page 15872 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver > Page 15873 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver > Page 15874 Seat Heater Switch: Locations Switch-Heated Seat-Passenger Component ID: 468 Component : SWITCH-HEATED SEAT-PASSENGER Connector: Name : SWITCH-HEATED SEAT-PASSENGER Color : GREEN # of pins : 6 Pin Description Circuit 1 GROUND Z302 20LG/BK 2 PANEL LAMPS DRIVER P301 20LG/OR 3 PASSENGER SEAT HEATER SUPPLY P95 18LG/WT 4 FUSED B(+) A930 16RD 5-6 FUSED B(+) A930 16RD Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver > Page 15875 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver > Page 15876 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver Seat Heater Switch: Diagrams Switch-Heated Seat-Driver Component ID: 467 Component : SWITCH-HEATED SEAT-DRIVER Connector: Name : SWITCH-HEATED SEAT-DRIVER Color : DK. GRAY # of pins : 6 Pin Description Circuit 1 GROUND Z301 20TN/BK 2 PANEL LAMPS DRIVER P301 20LG/OR 3 DRIVER SEAT HEATER SUPPLY P693 18LG/WT 4 FUSED B(+) A930 16RD 5-6 FUSED B(+) A930 16RD Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver > Page 15879 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver > Page 15880 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver > Page 15881 Seat Heater Switch: Diagrams Switch-Heated Seat-Passenger Component ID: 468 Component : SWITCH-HEATED SEAT-PASSENGER Connector: Name : SWITCH-HEATED SEAT-PASSENGER Color : GREEN # of pins : 6 Pin Description Circuit 1 GROUND Z302 20LG/BK 2 PANEL LAMPS DRIVER P301 20LG/OR 3 PASSENGER SEAT HEATER SUPPLY P95 18LG/WT 4 FUSED B(+) A930 16RD 5-6 FUSED B(+) A930 16RD Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver > Page 15882 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver > Page 15883 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Description Seat Heater Switch: Description and Operation Description DESCRIPTION Momentary contact push button switch/modules mounted in the instrument panel center bezel operate the heated seat system. Each heated seat switch/module has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected level (Low or High) of the seat heater. Pressing the switch/module button initiates heat. Heat remains on until switched off or until the ignition is turned off. If switched off by the ignition, a switch/module button must be pressed to restart heating. The switch/modules contain the solid state electronic control and diagnostic logic circuitry for the heated seat system. If any of the heated seat elements are inoperative or damaged one or more of the LED lamps in the switch/module for the effected seat will flash. The LED indicator lamps in each heated seat switch/module cannot be repaired. If the LED lamps are faulty or damaged, or the switch/module is inoperative or damaged the individual heated seat switch/module assembly must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Description > Page 15886 Seat Heater Switch: Description and Operation Operation OPERATION A Heated Seat Switch/Module is used to control the heated seat system. The heated seat switch/modules receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The switch/module responds to heated seat switch/module button input and ignition switch status inputs by controlling the 12v output to the front seat heating elements through integral solid-state relays. When either of the heated seat switch/module buttons are depressed the heating element for the selected seat is energized. Amber Light Emitting Diodes (LEDS) on the side of each switch/module indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. Pressing the switch/module button once will select high-level heating. Pressing the button a second time will select low-level heating. Pressing the button a third time will shut the heating elements off. The heated seat switch/module energizes an integral solid-state relay, which supplies battery current to the heating elements. When high-temperature heating is selected, the heaters provide a boosted heat level during the first four minutes of operation after heating is activated. The heat output then drops to the normal high-temperature level. If high-level heating is selected, the control system will automatically switch to the low level after two hours of continuous operation. At that time, the number of illuminated LEDs changes from two to one, indicating the change. Operation on the low setting will continue indefinitely until the switch/module button is pushed to turn the system off. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Removal Seat Heater Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. 3. Disconnect the switch/module electrical connectors. 4. Using an appropriate flat bladed tool, remove the heated seat switch/module from the bezel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Removal > Page 15889 Seat Heater Switch: Service and Repair Installation INSTALLATION 1. Align the tabs of the switch/module to the instrument panel center bezel and gently push together until the tabs are securely in place. 2. Connect the switch/module electrical connectors. 3. Install the instrument panel center bezel. 4. Connect the battery negative cable. 5. Verify heated seat system operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Sunroof / Moonroof Switch: Locations Component ID: 489 Component : SWITCH-SUNROOF Connector: Name : SWITCH-SUNROOF Color : BLACK # of pins : 4 A SUNROOF VENT SWITCH SENSE Q4 20OR/YL B SUNROOF SWITCH SUPPLY Q6 20OR/LG C SUNROOF OPEN SWITCH SENSE Q3 20OR/TN D SUNROOF CLOSE SWITCH SENSE Q5 20OR/LB Component Location - 53 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 15893 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 15894 Sunroof / Moonroof Switch: Diagrams Component ID: 489 Component : SWITCH-SUNROOF Connector: Name : SWITCH-SUNROOF Color : BLACK # of pins : 4 A SUNROOF VENT SWITCH SENSE Q4 20OR/YL B SUNROOF SWITCH SUPPLY Q6 20OR/LG C SUNROOF OPEN SWITCH SENSE Q3 20OR/TN D SUNROOF CLOSE SWITCH SENSE Q5 20OR/LB Component Location - 53 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 15895 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Description Sunroof / Moonroof Switch: Description and Operation Description DESCRIPTION The power sunroof switch (3) is a combination push-button and rocker switch module mounted in the overhead console. The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/module assembly. The sunroof switch performs the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed) The power sunroof switch is part of the overhead console assembly and cannot be replaced separately. If the switch is damaged or inoperative the overhead console must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Description > Page 15898 Sunroof / Moonroof Switch: Description and Operation Operation OPERATION The power sunroof switch is hard wired to the sunroof motor/module assembly. The switch receives battery current from the motor/module when the ignition switch is in the RUN and ACCESSORY positions. When one of the switch positions is pressed it sends battery current back to the motor/module, signaling it to move the power sunroof to the appropriate position. The motor/module will perform one of the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed) Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Page 15899 Sunroof / Moonroof Switch: Testing and Inspection SWITCH - POWER SUNROOF For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. If completing the appropriate diagnostic information results in the sunroof switch being inoperative, perform the following test prior to switch replacement. 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console. 3. Disconnect the power sunroof switch wire harness connector. 4. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. Refer to the POWER SUNROOF SWITCH CONTINUITY TABLE. If OK, inspect the wiring harness and connectors for damage. Use a scan tool and the proper Diagnostic Procedures Information to complete diagnosis of the power sunroof system. If not OK, replace the overhead console. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations Sound Proofing / Insulation: Locations NVH/SOUND DEADENER LOCATIONS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 15903 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 15904 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 15905 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Air Dam > Component Information > Service and Repair > Removal Air Dam: Service and Repair Removal REMOVAL 1. Remove the two outboard screws. 2. Remove the three middle screws and remove the air dam. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Air Dam > Component Information > Service and Repair > Removal > Page 15911 Air Dam: Service and Repair Installation INSTALLATION 1. Position the air dam onto the bumper and seat the carrot type fasteners fully. 2. Starting at the center screw install the three middle screws. 3. Install the two outboard screws. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Cover > Component Information > Service and Repair > Removal Tailgate Cover: Service and Repair Removal REMOVAL 1. Open the tailgate (1) and remove the tailgate liner, if equipped. 2. Remove the ten bolts (2) that secure the tailgate cover (3) to the inside of the tailgate and remove the cover. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Cover > Component Information > Service and Repair > Removal > Page 15917 Tailgate Cover: Service and Repair Installation INSTALLATION 1. Position the tailgate cover (3) onto the inside of the tailgate (1). 2. Install the ten bolts (2) that secure the tailgate cover to the tailgate. Tighten the bolts securely. 3. If equipped, install the tailgate liner onto the tailgate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Service and Repair > Removal Tailgate Hinge: Service and Repair Removal REMOVAL 1. Remove the tailgate. 2. If required, remove the bushing (3) from each tailgate hinge (1). 3. Remove the two bolts (4) that secure each tailgate hinge (1) to the cargo box (2) and remove the hinge(s) as necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Service and Repair > Removal > Page 15922 Tailgate Hinge: Service and Repair Installation INSTALLATION 1. Position the tailgate hinge(s) onto the cargo box (2) as necessary. 2. Install the two bolts (4) that secure each tailgate hinge to the cargo box. Tighten the bolts to 34 Nm (25 ft. lbs.). 3. If removed, install the bushing (3) onto each tailgate hinge. 4. Install the tailgate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Latch Tailgate Latch: Service and Repair Latch Removal REMOVAL 1. Open the tailgate and remove the tailgate liner, if equipped. 2. Remove the ten bolts (5) that secure the tailgate cover (4) to the inside of the tailgate and remove the cover. 3. Using a grease pencil or equivalent, mark the actuator rod (3) at the control (2) for the latch (1) being serviced. 4. Disconnect the actuator rod from the control. 5. Remove the two bolts (7 and 8) that secure the latch (5) to the tailgate (4) and position the tailgate check cable (6) out of the way. 6. Remove the latch and actuator rod from the tailgate as an assembly. 7. If required, remove the actuator rod from the latch. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Latch > Page 15927 1. If removed, install the actuator rod onto the latch (5) being serviced. 2. Install the latch and actuator rod into the tailgate (4) as an assembly. 3. Position the tailgate check cable (6) onto the tailgate and install the two bolts (7 and 8) that secure the latch and the check cable to the tailgate. Tighten the bolts to 23 Nm (17 ft. lbs.). 4. Locate the actuator rod (3) to the control (2) using the reference mark made during the removal procedure and connect the rod to the control. 5. Position the tailgate cover (4) onto the inside of the tailgate. 6. Install the ten bolts (5) that secure the tailgate cover to the tailgate. Tighten the bolts securely. 7. If equipped, install the tailgate liner onto the tailgate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Latch > Page 15928 Tailgate Latch: Service and Repair Latch Striker Removal REMOVAL 1. Open the tailgate and using a grease pencil or equivalent, mark the location of the tailgate striker (1) being serviced. 2. Remove the striker from the cargo box (2). Installation INSTALLATION 1. Position the striker (1) onto the cargo box (2) using the reference mark made during the removal procedure. 2. Tighten the striker to 34 Nm (25 ft. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > Removal Tailgate Release Handle: Service and Repair Removal REMOVAL 1. Open the tailgate and remove the tailgate liner, if equipped. 2. Remove the ten bolts (5) that secure the tailgate cover (4) to the inside of the tailgate and remove the cover. 3. Using a grease pencil or equivalent, mark the location of the actuator rods (3) at the control (2). 4. Disconnect the actuator rods from the control. 5. Remove the two nuts (3) that secure the release handle (1) and the control (2) to the tailgate (4). 6. Remove the control and the release handle from the tailgate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > Removal > Page 15933 Tailgate Release Handle: Service and Repair Installation INSTALLATION 1. Position the release handle and the control onto the tailgate. 2. Install the two nuts that secure the release handle and control to the tailgate. Tighten the nuts to 7 Nm (60 in. lbs.). 3. Locate the actuator rods (3) to the control (2) using the reference marks made during the removal procedure and connect the rods to the control. 4. Position the tailgate cover (4) onto the inside of the tailgate. 5. Install the ten bolts (5) that secure the tailgate cover to the tailgate. Tighten the bolts securely. 6. If equipped, install the tailgate liner onto the tailgate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Service and Repair > Removal Tailgate Shock / Support: Service and Repair Removal REMOVAL 1. Open the tailgate and locate the tailgate check cable (3) on the left and right of the cargo box below the tailgate striker (1) as necessary. 2. Pry the cable lock tab(s) (4) outward using a screwdriver or flat bladed tool (2) and remove the tailgate check cable(s) from the cargo box. 3. Remove the bolt (1) that secures the tailgate check cable (2) to the left and right side of the tailgate (3) as necessary. 4. Remove the tailgate check cable(s) from the tailgate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Service and Repair > Removal > Page 15938 Tailgate Shock / Support: Service and Repair Installation INSTALLATION 1. Position the tailgate check cable (2) onto the left and right side of the tailgate (3) as necessary. 2. Install the bolt (1) that secures the small end of the tailgate check cable(s) to the tailgate. Tighten the bolt(s) to 23 Nm (17 ft. lbs.). 3. Position the tailgate check cable (3) to the left and right side of the cargo box below the tailgate striker (1) as necessary. 4. Install the large end of the tailgate check cable(s) onto the cargo box. Make sure that the cable lock tab(s) (4) fully engage. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Towing Hook / Bracket > Component Information > Service and Repair > Removal Towing Hook / Bracket: Service and Repair Removal REMOVAL 1. Remove front bumper. 2. Remove the bolts (2) and remove the tow hook assembly (3). 3. If the vehicle is a Heavy Duty, then remove the bolts (1) and remove the tow hook (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Towing Hook / Bracket > Component Information > Service and Repair > Removal > Page 15943 Towing Hook / Bracket: Service and Repair Installation INSTALLATION 1. Install the tow hook assembly (3) and bolts (2) hand tight. 2. If vehicle is a Heavy Duty, install the tow hook (2) and bolts (1) hand tight. 3. Install the front bumper. 4. Line up the tow hooks/tow hook assembly and tighten the bolts to 68 Nm (50 ft. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box Truck Bed: Service and Repair Cargo Box Removal REMOVAL NOTE: Long cargo box shown in illustration. Short cargo box similar. 1. Remove the screws (1) that secure the fuel filler (2) to the cargo box (3). 2. Remove the fuel filler from the cargo box and position it out of the way. 3. If necessary, remove the fuel filler door from the cargo box. 4. Disconnect the tail lamp wire harness from the underbody wire harness. 5. If necessary, remove the tail lamp units and wire harness from the cargo box. 6. If necessary, remove the tailgate. 7. If necessary, remove the rear bumper. 8. Remove the bolts (3) that secure the cargo box (1) to the frame (2) (six short box, eight long box) and remove the cargo box. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box > Page 15948 NOTE: Long cargo box shown in illustration. Short cargo box similar. 1. Position the cargo box (1) onto the frame (2) and loosely install the bolts (3) (six short box, eight long box). 2. Align the cargo box to the cab and tighten the bolts to 108 Nm (80 ft. lbs.). 3. If removed, install tail lamp units and wire harness onto the cargo box. 4. Connect the tail lamp wire harness to the underbody wire harness. 5. If removed, install the tailgate. 6. If removed, install the rear bumper. 7. If removed, install the fuel filler door. 8. Position the fuel filler (2) to the cargo box (3). 9. Install the screws (1) that secure the fuel filler to the cargo box. Tighten the screws to 2.2 Nm (20 in. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box > Page 15949 Truck Bed: Service and Repair Cargo Box - Tie Down Removal REMOVAL 1. Remove the two bolts (1) that secure each cargo box tie down (2) to the cargo bed and remove the cleats as necessary. Installation INSTALLATION 1. Position the cargo box tie downs (2) to the cargo box as necessary. 2. Install the two bolts (1) that secure each cargo box tie down to the cargo box. Tighten the bolts to 34 Nm (25 ft. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Service and Repair > Removal Cowl: Service and Repair Removal REMOVAL 1. Remove the wiper arms. 2. Disconnect the cowl plenum washer hose from the washer supply hose at the molded plastic in-line fitting. 3. Remove the cowl weather seal from the front of the dash panel and the cowl grille (2). 4. Remove the six push pin fasteners (1) that secure the front of the cowl grille to the dash panel. 5. Remove the two screws (3) that secure the rear corners of the cowl grille to the dash panel and remove the grille. 6. If necessary, remove the washer nozzles and the cowl plenum washer hose from the cowl grille. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Service and Repair > Removal > Page 15955 Cowl: Service and Repair Installation INSTALLATION 1. If removed, install the washer nozzles and the cowl plenum washer hose onto the cowl grille (2). 2. Position the cowl grille onto the dash panel. 3. Install the two screws (3) and the six push-pin fasteners (1) that secure the cowl grille to the dash panel. 4. Install the cowl weather seal onto the front of the dash panel and the cowl grille. 5. Connect the cowl plenum washer hose to the washer supply hose at the molded plastic in-line fitting. 6. Install the wiper arms. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip Front Door Weatherstrip: Service and Repair Drip Rail Weatherstrip Removal REMOVAL 1. Open the doors and separate the weatherstrip (3) from the drip rail and a-pillar retainers (1 and 7). Installation INSTALLATION 1. Position the weatherstrip (3) onto the drip rail and a-pillar retainers (1 and 7) and seat fully. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 15961 Front Door Weatherstrip: Service and Repair A-Pillar Weatherstrip Retainer Removal REMOVAL 1. Remove the drip rail weatherstrip retainer (1) 2. Remove the five screws (8) and remove the A-pillar weatherstrip retainer (7). Installation INSTALLATION 1. Install the A-pillar weatherstrip retainer (7) and install the screws (8). 2. Install the drip rail weatherstrip retainer (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 15962 Front Door Weatherstrip: Service and Repair Door Opening Seal Removal REMOVAL FRONT DOOR SEAL 1. Remove the cowl trim panel (1). 2. If vehicle is a Standard Cab, remove the lower b-pillar trim panel (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 15963 3. If vehicle is a Quad Cab, remove the lower b-pillar trim panel (1). 4. Separate the front door opening seal (6) from the door opening flange. REAR DOOR SEAL 1. Remove the lower b-pillar trim panel (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 15964 2. Remove the lower c-pillar trim (1). 3. Separate the rear door opening seal (5) from the door opening flange. Installation INSTALLATION FRONT DOOR SEAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 15965 1. Position the front door seal (6) to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. If vehicle is a Standard Cab, install the lower b-pillar trim (3). 3. If vehicle is a Quad Cab, install the lower b-pillar trim (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 15966 4. Install the cowl trim panel (1). NOTE: When installing a new weatherstrip on the front door opening, remove the tear strip starting at the splice and moving around the front of the door to the back of the opening. REAR DOOR SEAL 1. Position the rear door seal to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 15967 2. Install the lower c-pillar trim (1). 3. Install the lower b-pillar trim (1). NOTE: When installing a new weatherstrip on the rear door opening, remove the tear strip starting at the splice and moving around the back of the door to the front of the opening. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 15968 Front Door Weatherstrip: Service and Repair Drip Rail Weatherstrip Retainer Removal REMOVAL 1. Separate the drip rail weatherstrip (3) from the weatherstrip retainer (1). 2. Remove the seven screws (2) and remove the retainer (1). Installation INSTALLATION 1. Install the weatherstrip retainer (1) and install the seven screws (2). 2. Position the weatherstrip (3) over the retainer flange and seat fully. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding Front Door Window Glass Weatherstrip: Service and Repair Front Door Outer Belt Molding Removal REMOVAL 1. Remove the screw (4) and separate the belt molding (1) from the door (5) flange from the back to the front. Installation INSTALLATION 1. Position the belt molding (1) onto the door (5) flange and seat fully. 2. Install the screw (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 15973 Front Door Window Glass Weatherstrip: Service and Repair Front Door Glass Run Weatherstrip Removal REMOVAL 1. Remove the door glass. 2. Separate the front door glass run weatherstrip (2) out of the door frame (5) and remove through the window opening. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 15974 NOTE: A mixture of soap and water may be used to aid installation of the weatherstrip into the corners. 1. Position the front door glass run weatherstrip (2) into the door (5) through the window opening. 2. Position the weatherstrip into the upper corners and seat firmly. 3. From back to front, seat the weatherstrip between the corners and then down the sides firmly. 4. Install the door glass. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 15975 Front Door Window Glass Weatherstrip: Service and Repair Front Door Inner Belt Molding Removal REMOVAL 1. Remove the door trim panel (3). 2. Separate the belt molding (1) from the door (3) mounting flange from the back to the front. Installation INSTALLATION 1. Position the belt molding (1) and seat onto the door (3) mounting flange fully. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 15976 2. Install the door trim panel (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip Rear Door Weatherstrip: Service and Repair Drip Rail Weatherstrip Removal REMOVAL 1. Open the doors and separate the weatherstrip (3) from the drip rail and a-pillar retainers (1 and 7). Installation INSTALLATION 1. Position the weatherstrip (3) onto the drip rail and a-pillar retainers (1 and 7) and seat fully. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 15981 Rear Door Weatherstrip: Service and Repair A-Pillar Weatherstrip Retainer Removal REMOVAL 1. Remove the drip rail weatherstrip retainer (1) 2. Remove the five screws (8) and remove the A-pillar weatherstrip retainer (7). Installation INSTALLATION 1. Install the A-pillar weatherstrip retainer (7) and install the screws (8). 2. Install the drip rail weatherstrip retainer (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 15982 Rear Door Weatherstrip: Service and Repair Drip Rail Weatherstrip Retainer Removal REMOVAL 1. Separate the drip rail weatherstrip (3) from the weatherstrip retainer (1). 2. Remove the seven screws (2) and remove the retainer (1). Installation INSTALLATION 1. Install the weatherstrip retainer (1) and install the seven screws (2). 2. Position the weatherstrip (3) over the retainer flange and seat fully. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 15983 Rear Door Weatherstrip: Service and Repair Door Opening Seal Removal REMOVAL FRONT DOOR SEAL 1. Remove the cowl trim panel (1). 2. If vehicle is a Standard Cab, remove the lower b-pillar trim panel (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 15984 3. If vehicle is a Quad Cab, remove the lower b-pillar trim panel (1). 4. Separate the front door opening seal (6) from the door opening flange. REAR DOOR SEAL 1. Remove the lower b-pillar trim panel (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 15985 2. Remove the lower c-pillar trim (1). 3. Separate the rear door opening seal (5) from the door opening flange. Installation INSTALLATION FRONT DOOR SEAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 15986 1. Position the front door seal (6) to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. If vehicle is a Standard Cab, install the lower b-pillar trim (3). 3. If vehicle is a Quad Cab, install the lower b-pillar trim (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 15987 4. Install the cowl trim panel (1). NOTE: When installing a new weatherstrip on the front door opening, remove the tear strip starting at the splice and moving around the front of the door to the back of the opening. REAR DOOR SEAL 1. Position the rear door seal to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 15988 2. Install the lower c-pillar trim (1). 3. Install the lower b-pillar trim (1). NOTE: When installing a new weatherstrip on the rear door opening, remove the tear strip starting at the splice and moving around the back of the door to the front of the opening. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Outer Belt Molding Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Outer Belt Molding Removal REMOVAL 1. Remove the screw (3) and separate the belt molding (1) from the door (2) flange from the back to the front. Installation INSTALLATION 1. Position the belt molding (1) onto the door (2) flange and seat fully. 2. Install the screw (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Outer Belt Molding > Page 15993 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Run Weatherstrip Removal REMOVAL 1. Lower the glass. 2. Separate the rear door glass run weatherstrip (5) out of the door frame (2) and remove through the window opening. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Outer Belt Molding > Page 15994 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Outer Belt Molding > Page 15995 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Inner Belt Molding Removal REMOVAL 1. Remove the door trim panel (5). 2. Separate the belt molding (2) from the rear door mounting flange from the back to the front. Installation INSTALLATION 1. Position the belt molding (2) and seat onto the rear door mounting flange fully. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Outer Belt Molding > Page 15996 2. Install the door trim panel (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations Cruise Control Servo: Locations Component ID: 439 Component : SERVO-SPEED CONTROL Connector: Name : SERVO-SPEED CONTROL Color : BLACK # of pins : 4 Qualifier : (GAS EXCEPT 3.7L/5.7L) Pin Description Circuit 1 S/C VACUUM SOL CONTROL V36 20VT/YL 2 S/C VENT SOL CONTROL V35 20VT/OR 3 S/C BRAKE SWITCH OUTPUT V30 20VT/WT 4 GROUND Z913 20BK Component Location - 32 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 16001 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 16002 Cruise Control Servo: Diagrams Component ID: 439 Component : SERVO-SPEED CONTROL Connector: Name : SERVO-SPEED CONTROL Color : BLACK # of pins : 4 Qualifier : (GAS EXCEPT 3.7L/5.7L) Pin Description Circuit 1 S/C VACUUM SOL CONTROL V36 20VT/YL 2 S/C VENT SOL CONTROL V35 20VT/OR 3 S/C BRAKE SWITCH OUTPUT V30 20VT/WT 4 GROUND Z913 20BK Component Location - 32 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 16003 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Description and Operation > Description Cruise Control Servo: Description and Operation Description DESCRIPTION A speed control servo is not used with any 3.7L V-6, 5.7L V-8 engine, or 5.9L diesel engine. The speed control servo is attached to the bottom of the battery tray. The servo unit consists of a solenoid valve body, and a vacuum chamber. The solenoid valve body contains three solenoids: - Vacuum - Vent - Dump The vacuum chamber contains a diaphragm with a cable attached to control the throttle linkage. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Description and Operation > Description > Page 16006 Cruise Control Servo: Description and Operation Operation OPERATION A speed control servo is not used with any 3.7L V-6, 5.7L V-8 engine, or 5.9L diesel engine. The following information applies only to vehicles equipped with a mechanical servo. When/if a servo is used on gasoline powered vehicles, the Powertrain Control Module (PCM) controls the solenoid valve body. The solenoid valve body controls the application and release of vacuum to the diaphragm of the vacuum servo. The servo unit cannot be repaired and is serviced only as a complete assembly. Power is supplied to the servo's by the PCM through the brake switch. The PCM controls the ground path for the vacuum and vent solenoids. The dump solenoid is energized anytime it receives power. If power to the dump solenoid is interrupted, the solenoid dumps vacuum in the servo. This provides a safety backup to the vent and vacuum solenoids. The vacuum and vent solenoids must be grounded at the PCM to operate. When the PCM grounds the vacuum servo solenoid, the solenoid allows vacuum to enter the servo and pull open the throttle plate using the cable. When the PCM breaks the ground, the solenoid closes and no more vacuum is allowed to enter the servo. The PCM also operates the vent solenoid via ground. The vent solenoid opens and closes a passage to bleed or hold vacuum in the servo as required. The PCM duty cycles the vacuum and vent solenoids to maintain the set speed, or to accelerate and decelerate the vehicle. To increase throttle opening, the PCM grounds the vacuum and vent solenoids. To decrease throttle opening, the PCM removes the grounds from the vacuum and vent solenoids. When the brake is released, if vehicle speed exceeds 30 mph (48.2kph) to resume, 35 mph (56.3 kph) to set, and the RES/ACCEL switch has been depressed, ground for the vent and vacuum circuits is restored. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Service and Repair > Removal Cruise Control Servo: Service and Repair Removal REMOVAL A speed control servo is used only with the 4.7L V-8 engine. The speed control servo assembly is attached to the bottom of the battery tray (1) . 1. Disconnect negative battery cable at battery (both cables at both batteries if diesel). 2. To gain access to servo, remove plastic wheelhouse splash shield over left-front wheel. 3. Disconnect vacuum line (7) at servo . 4. Disconnect electrical connector (4) at servo . 5. Remove 3 servo mounting screws (5) . Depending on engine application, different sets of mounting lugs (2) are used to support servo to battery tray. While removing, note proper lugs. 6. Disconnect servo cable at throttle body. 7. Remove 2 mounting nuts (1) holding servo cable sleeve to bracket . 8. Pull speed control cable sleeve and servo away from servo mounting bracket to expose cable retaining clip (3) and remove clip. Note: The servo mounting bracket displayed is a typical bracket and may/may not be applicable to this model vehicle. 9. Remove servo (2) from mounting bracket. While removing, note orientation of servo to bracket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Service and Repair > Removal > Page 16009 Cruise Control Servo: Service and Repair Installation INSTALLATION A speed control servo is used only with the 4.7L V-8 engine. 1. Position servo to mounting bracket . 2. Align hole in cable connector with hole in servo pin. Install cable-to-servo retaining clip . 3. Insert servo mounting studs through holes in servo mounting bracket. 4. Install 2 servo-to-mounting bracket nuts and tighten to 60 in. lbs. (7 Nm). 5. Position servo assembly to correct mounting lugs on battery tray and install 3 screws. Tighten to 30 in. lbs. (4 Nm). 6. Connect vacuum line at servo. 7. Connect electrical connector at servo. 8. Connect servo cable to throttle body. 9. Install left-front wheel-well liner. 10. Connect negative battery cable to battery (connect both cables if diesel). 11. Before starting engine, operate accelerator pedal to check for any binding. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Switch-Speed Control-Left Cruise Control Switch: Diagrams Switch-Speed Control-Left Component ID: 486 Component : SWITCH-SPEED CONTROL-LEFT Connector: Name : SWITCH-SPEED CONTROL-LEFT Color : BLACK # of pins : 3 A S/C SWITCH NO. 2 SIGNAL V38 22VT/OR B S/C SWITCH RETURN V937 22DB/DG B SENSOR GROUND K900 22DB/DG C S/C SWITCH NO. 1 SIGNAL V37 22VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Switch-Speed Control-Left > Page 16014 Cruise Control Switch: Diagrams Switch-Speed Control-Right Component ID: 487 Component : SWITCH-SPEED CONTROL-RIGHT Connector: Name : SWITCH-SPEED CONTROL-RIGHT Color : BLACK # of pins : 3 A S/C SWITCH NO. 2 SIGNAL V38 22VT/OR B S/C SWITCH RETURN V937 22DB/DG B SENSOR GROUND K900 22DB/DG C S/C SWITCH NO. 1 SIGNAL V37 22VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Description Cruise Control Switch: Description and Operation Description DESCRIPTION Two separate switch pods operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM (to the ECM for diesel) for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the Owner's Manual for speed control switch functions and setting procedures. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Depending on engine control computer (JTEC having a 3- plug connector or NGC having a 4- plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switch used with the NGC system has an attached pigtail lead. The switch used with the JTEC system does not have an attached pigtail lead. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Description > Page 16017 Cruise Control Switch: Description and Operation Operation OPERATION When speed control is selected by depressing the ON, OFF switch, the PCM (ECM for diesel) allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 (56.2kph) and 85 mph (136.8kph). In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: - Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: - An indication of Park or Neutral (auto. trans.) - The VSS signal increases at a rate of 10 mph (16 kph) per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - Depressing the clutch pedal (manual trans.). - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph (16 kph) per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph (32.1 kph) of the set speed - The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM (ECM for diesel). NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's/ECM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM (ECM for diesel) is programmed for an acceleration feature. With the ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the PCM's/ECM's RAM when the ACCEL switch is released. The PCM/ECM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph (3.2 kph) for each momentary switch activation of the ACCEL switch. The PCM/ECM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached. Then release the switch. The ON, OFF switch operates two components: the PCM's/ECM's ON, OFF input, and the battery voltage to the brake switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Removal Cruise Control Switch: Service and Repair Removal REMOVAL Depending on engine control computer (JTEC having a 3-plug connector or 5.7L V-8 NGC having a 4-plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switches used with the NGC system have attached pigtail leads . The switch used with the JTEC system does not have an attached pigtail lead. 1. Remove switch mounting screw (2). 2. Pull switch (2) from steering wheel. 3. Unplug electrical connector from switch, or, if equipped, switch pigtail wire harness from steering wheel wire harness (4) and remove switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Removal > Page 16020 Cruise Control Switch: Service and Repair Installation INSTALLATION 1. Plug electrical connector into switch, or, if equipped, connect pigtail wire harness to steering wheel wire harness. Be sure wires are not pinched. 2. Position switch to steering wheel. 3. Install switch mounting screw and tighten 15 in. lbs. ( 1.7 Nm). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Description and Operation > Description Cruise Control Vacuum Reservoir: Description and Operation Description DESCRIPTION The vacuum reservoir is a plastic storage tank connected to an engine vacuum source by vacuum lines. A vacuum reservoir is not used with diesel engines, or with 3.7L or 5.7L gas powered engines. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Description and Operation > Description > Page 16025 Cruise Control Vacuum Reservoir: Description and Operation Operation OPERATION The vacuum reservoir is used to supply the vacuum needed to maintain proper speed control operation when engine vacuum drops, such as in climbing a grade while driving. A one-way check valve is used in the vacuum line between the reservoir and the vacuum source. This check valve is used to trap engine vacuum in the reservoir. On certain vehicle applications, this reservoir is shared with the heating/air-conditioning system. The vacuum reservoir cannot be repaired and must be replaced if faulty. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Description and Operation > Page 16026 Cruise Control Vacuum Reservoir: Testing and Inspection VACUUM RESERVOIR 1. Disconnect vacuum hose at speed control servo and install a vacuum gauge into the disconnected hose. 2. Start engine and observe gauge at idle. Vacuum gauge should read at least ten inches of mercury. 3. If vacuum is less than ten inches of mercury, determine source of leak. Check vacuum line to engine for leaks. Also check actual engine intake manifold vacuum. If manifold vacuum does not meet this requirement, check for poor engine performance and repair as necessary. 4. If vacuum line to engine is not leaking, check for leak at vacuum reservoir. To locate and gain access to reservoir, refer to Vacuum Reservoir Removal/Installation. Disconnect vacuum line at reservoir and connect a hand-operated vacuum pump to reservoir fitting. Apply vacuum. Reservoir vacuum should not bleed off. If vacuum is being lost, replace reservoir. 5. Verify operation of one-way check valve and check it for leaks. Certain models may be equipped with 2 check-valves. a. Locate one-way check valve. The valve is located in vacuum line between vacuum reservoir and engine vacuum source. Disconnect vacuum hoses (lines) at each end of valve. b. Connect a hand-operated vacuum pump to reservoir end of check valve. Apply vacuum. Vacuum should not bleed off. If vacuum is being lost, replace one-way check valve. c. Connect a hand-operated vacuum pump to vacuum source end of check valve. Apply vacuum. Vacuum should flow through valve. If vacuum is not flowing, replace one-way check valve. Seal the fitting at opposite end of valve with a finger and apply vacuum. If vacuum will not hold, diaphragm within check valve has ruptured. Replace valve. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Service and Repair > Removal Cruise Control Vacuum Reservoir: Service and Repair Removal REMOVAL The vacuum reservoir (1) is located in the engine compartment under the fresh air cowl grill panel . 1. Remove wiper blades and arms. 2. Remove fresh air cowl grill. 3. Disconnect vacuum line (2) at reservoir . 4. Remove 2 reservoir mounting nuts (3) . 5. Remove reservoir from cowl. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Service and Repair > Removal > Page 16029 Cruise Control Vacuum Reservoir: Service and Repair Installation INSTALLATION 1. Position reservoir onto 2 weld studs . 2. Install 2 mounting nuts and tighten to 20 in. lbs. (3 Nm). 3. Connect vacuum line to reservoir fitting. 4. Install cowl grill. 5. Install wiper arms / blades. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Switch-Speed Control-Left Cruise Control Switch: Diagrams Switch-Speed Control-Left Component ID: 486 Component : SWITCH-SPEED CONTROL-LEFT Connector: Name : SWITCH-SPEED CONTROL-LEFT Color : BLACK # of pins : 3 A S/C SWITCH NO. 2 SIGNAL V38 22VT/OR B S/C SWITCH RETURN V937 22DB/DG B SENSOR GROUND K900 22DB/DG C S/C SWITCH NO. 1 SIGNAL V37 22VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Switch-Speed Control-Left > Page 16035 Cruise Control Switch: Diagrams Switch-Speed Control-Right Component ID: 487 Component : SWITCH-SPEED CONTROL-RIGHT Connector: Name : SWITCH-SPEED CONTROL-RIGHT Color : BLACK # of pins : 3 A S/C SWITCH NO. 2 SIGNAL V38 22VT/OR B S/C SWITCH RETURN V937 22DB/DG B SENSOR GROUND K900 22DB/DG C S/C SWITCH NO. 1 SIGNAL V37 22VT Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Description Cruise Control Switch: Description and Operation Description DESCRIPTION Two separate switch pods operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM (to the ECM for diesel) for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the Owner's Manual for speed control switch functions and setting procedures. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Depending on engine control computer (JTEC having a 3- plug connector or NGC having a 4- plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switch used with the NGC system has an attached pigtail lead. The switch used with the JTEC system does not have an attached pigtail lead. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Description > Page 16038 Cruise Control Switch: Description and Operation Operation OPERATION When speed control is selected by depressing the ON, OFF switch, the PCM (ECM for diesel) allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 (56.2kph) and 85 mph (136.8kph). In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: - Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: - An indication of Park or Neutral (auto. trans.) - The VSS signal increases at a rate of 10 mph (16 kph) per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - Depressing the clutch pedal (manual trans.). - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph (16 kph) per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph (32.1 kph) of the set speed - The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM (ECM for diesel). NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's/ECM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM (ECM for diesel) is programmed for an acceleration feature. With the ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the PCM's/ECM's RAM when the ACCEL switch is released. The PCM/ECM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph (3.2 kph) for each momentary switch activation of the ACCEL switch. The PCM/ECM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached. Then release the switch. The ON, OFF switch operates two components: the PCM's/ECM's ON, OFF input, and the battery voltage to the brake switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Removal Cruise Control Switch: Service and Repair Removal REMOVAL Depending on engine control computer (JTEC having a 3-plug connector or 5.7L V-8 NGC having a 4-plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switches used with the NGC system have attached pigtail leads . The switch used with the JTEC system does not have an attached pigtail lead. 1. Remove switch mounting screw (2). 2. Pull switch (2) from steering wheel. 3. Unplug electrical connector from switch, or, if equipped, switch pigtail wire harness from steering wheel wire harness (4) and remove switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Removal > Page 16041 Cruise Control Switch: Service and Repair Installation INSTALLATION 1. Plug electrical connector into switch, or, if equipped, connect pigtail wire harness to steering wheel wire harness. Be sure wires are not pinched. 2. Position switch to steering wheel. 3. Install switch mounting screw and tighten 15 in. lbs. ( 1.7 Nm). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation > Description ABS Light: Description and Operation Description DESCRIPTION An Antilock Brake System (ABS) indicator is standard equipment on all instrument clusters. However, the instrument cluster can be programmed to disable this indicator on vehicles that are not equipped with the ABS or Rear Wheel Anti-Lock (RWAL) brake systems, which are not available in some markets. This indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. The ABS indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Failure of Anti-lock Braking System in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ABS indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation > Description > Page 16047 ABS Light: Description and Operation Operation OPERATION The ABS indicator gives an indication to the vehicle operator when the ABS system, or a circuit or component of the system is ineffective. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Controller Area Network (CAN) data bus. The ABS indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the ABS indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the ABS indicator is illuminated for about four seconds as a bulb test. The entire bulb test is a function of the CAB. - ABS Indicator Lamp-On Message - Each time the cluster receives an electronic ABS indicator lamp-ON message from the CAB, the ABS indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the CAB for five consecutive message cycles, the ABS indicator is illuminated. The indicator remains illuminated until the cluster receives a valid message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the instrument cluster is put through the actuator test, the ABS indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. - ABS Diagnostic Test - The ABS indicator is blinked ON and OFF by lamp-ON and lamp-OFF messages from the CAB during the performance of the ABS diagnostic tests. The CAB continually monitors the ABS circuits and sensors to decide whether the system is in good operating condition. The CAB then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the CAB sends a lamp-ON message after the bulb test, it indicates that the CAB has detected a system malfunction or that the ABS system has become ineffective. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the ABS indicator fails to light due to an open or short in the cluster ABS indicator circuit, the cluster sends a message notifying the CAB of the condition, then the instrument cluster and the CAB will each store a DTC. For proper diagnosis of the antilock brake system, the CAB, the EMIC, the CAN data bus or the electronic communication related to ABS indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Description Audible Warning Device: Description and Operation Description DESCRIPTION A chime warning system is standard factory-installed equipment. The chime warning system uses an electromechanical transducer and an electromechanical relay that are soldered onto the electronic circuit board inside of the ElectroMechanical Instrument Cluster (EMIC) (1) to provide audible indications of various vehicle conditions that may require the attention of the vehicle operator or occupants. The EMIC also includes the hardware and software necessary to serve as the electronic body control module and is sometimes referred to as the Cab Compartment Node or CCN. The electromechanical transducer generates beep tones and chime tones, while the electromechanical relay generates click tones to emulate the sounds associated with conventional turn signal and hazard warning flasher operation. The microprocessor-based EMIC utilizes electronic chime request messages received from other modules in the vehicle over the Controller Area Network (CAN) data bus along with hard wired inputs to monitor many sensors and switches throughout the vehicle. In response to those inputs, the circuitry and programming of the EMIC allow it to control the audible outputs that are produced through its on-board transducer and relay. The EMIC is capable of producing the following audible outputs: - Slow Rate Repetitive Click - Repeated click tones that are issued at a slow rate of about 50 clicks per minute. - Fast Rate Repetitive Click - Repeated click tones that are issued at a fast rate of more than about 100 clicks per minute. Fixed Duration Beep - A short, sharp, single tactile beep tone. - Single Chime Tone - A single chime tone. - Slow Rate Repetitive Chime - Repeated chime tones that are issued at a slow rate of about 50 chimes per minute. - Fast Rate Repetitive Chime - Repeated chime tones that are issued at a fast rate of about 180 chimes per minute. Hard wired circuitry connects the EMIC and the various chime warning system switch and sensor inputs to their modules and to each other through the electrical system of the vehicle. These hard wired circuits are integral to several wire harnesses, which are routed throughout the vehicle and retained by many different methods. These circuits may be connected to each other, to the vehicle electrical system and to the EMIC through the use of a combination of soldered splices, splice block connectors, and many different types of wire harness terminal connectors and insulators. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. The EMIC chime warning system circuits and components cannot be adjusted or repaired. If the EMIC circuitry, the on-board transducer or the relay are Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Description > Page 16052 damaged or ineffective, the EMIC unit must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Description > Page 16053 Audible Warning Device: Description and Operation Operation OPERATION The chime warning system operates on battery voltage received through a fuse in the Totally Integrated Power Module (TIPM) on a non-switched fused B(+) circuit so that the system may operate regardless of the ignition switch position. The chime warning system also monitors the ignition switch position so that some chime features are functional only with the ignition switch in the ON position, while others are functional regardless of the ignition switch position. The chime warning system provides an audible indication to the vehicle operator or occupants under the following conditions: - Airbag Indicator Warning - The ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) transducer will generate one short chime when the ignition switch is in the ON position, and an electronic message is received over the Controller Area Network (CAN) data bus from the Occupant Restraint Controller (ORC) requesting airbag indicator illumination. This warning will only occur following completion of the airbag indicator bulb test, and will only occur once during any ignition cycle. - Compass Mini-Trip Computer Global Reset - The EMIC transducer will generate one short chime when the ignition switch is in the ON position, and an electronic message is received over the CAN data bus from the optional Compass Mini-Trip Computer (CMTC) requesting that the CMTC average fuel economy, trip odometer and distance to empty data be reset. The CMTC monitors hard wired inputs from the US/M (United States/Metric) and RESET button switches to determine the proper reset messages to send to the EMIC. - Door Ajar Indicator Warning - The EMIC transducer will generate one short chime when the ignition switch is in the ON position, a hard wired input is received indicating that the status of any door ajar switch has changed, and an electronic message is received over the CAN data bus indicating that the vehicle is moving. - Electronic Stability Program/Brake Assist System Warning - The EMIC transducer will generate one short chime when the Electronic Stability Program (ESP)/Brake Assist System (BAS) has been manually disabled by the vehicle operator using the ESP/BAS traction control switch on the instrument panel. - Electronic Stability Program/Brake Assist System Fault Warning - The EMIC transducer will generate one short chime each time the Electronic Stability Program (ESP)/Brake Assist System (BAS) indicator is illuminated in the instrument cluster. This warning indicates a failure condition has been monitored affecting the operation of the ESP/BAS related components or circuits. This warning will only occur following completion of the ESP/BAS indicator bulb test, and will only occur once during any ignition cycle. - Engine Coolant Temperature High Warning (Diesel Engine Only) - The EMIC transducer will generate a single chime tone when the check gauges indicator is illuminated for a high or critical engine coolant temperature condition. The EMIC uses electronic engine coolant temperature messages received from the diesel Engine Control Module (ECM) over the CAN data bus to illuminate the check gauges indicator for a coolant temperature high condition. - Electronic Vehicle Information Center Data Reset - The EMIC transducer will generate one short chime when the ignition switch is in the ON position, and an electronic message is received over the CAN data bus from the optional Electronic Vehicle Information Center (EVIC) requesting that the EVIC average fuel economy, trip odometer, distance to empty or customer programmable features data be reset. The EVIC monitors hard wired inputs from the EVIC control push button switches to determine the proper reset messages to send to the EMIC. - Fasten Seat Belt Indicator Warning - The EMIC transducer will generate repetitive chimes at a slow rate to announce that a hard wired input from the seat belt switch indicates that the driver side front seat belt is not fastened with the ignition switch in the ON position. The chime warning system also supports the enhanced seatbelt reminder (beltminder) when this feature is enabled. - Head/Park Lamps-On Warning - The EMIC transducer will generate repetitive chimes at a fast rate to indicate that hard wired inputs from the driver door ajar switch, the headlamp switch, and the ignition switch indicate that the exterior lamps are turned ON with the driver side front door opened and the ignition switch in the OFF position. The chimes will continue to sound until the exterior lamps are turned OFF, the driver side front door is closed, or the ignition switch is turned to the ON position, whichever occurs first. - Key-In-Ignition Warning - The EMIC transducer will generate repetitive chimes at a fast rate to indicate that hard wired inputs from the driver door ajar switch, the ignition switch, and the key-in ignition switch circuitry of the ignition switch indicate that the key is in the ignition lock cylinder with the driver side front door open and the ignition switch in the OFF position. The chimes will continue to sound until the key is removed from the ignition lock cylinder, the driver side front door is closed, or the ignition switch is turned to the ON position, whichever occurs first. - Low Fuel Indicator Warning - The EMIC transducer will generate one short chime when the low fuel indicator is illuminated by the instrument cluster circuitry. This chime will only occur once during any ignition cycle. - Low Oil Pressure Warning (Diesel Engine Only) - The EMIC transducer will generate repetitive chimes at a fast rate when the check gauges indicator is illuminated for a low oil pressure condition. The EMIC uses electronic engine speed and oil pressure messages received from the diesel Engine Control Module (ECM) over the CAN data bus indicating that the engine is running and that the oil pressure is low to illuminate the check gauges indicator. The chimes will continue to sound for five seconds, until the oil pressure message indicates that the oil pressure is not low, or until the engine speed message indicates that the engine is not running, whichever occurs first. This chime will only occur once during any ignition cycle. - Low Wash Indicator Warning - The EMIC transducer will generate one short chime when the low washer fluid indicator is illuminated by the instrument cluster circuitry. This chime will only occur once during any ignition cycle. - Overspeed Warning - The EMIC transducer will generate repetitive chimes at a slow rate to indicate that the vehicle speed is over a pre-programmed speed value. The EMIC monitors electronic vehicle speed messages received over the CAN data bus. This feature is only enabled on an EMIC that has been programmed with a Middle East Gulf Coast Country (GCC) country code. - Park Brake Reminder - The EMIC transducer will generate one short chime to announce that the hard wired input from the park brake switch Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Description > Page 16054 and an electronic vehicle speed message received over the CAN data bus indicate that the park brake is applied and the vehicle is moving. This chime will repeat each time the input conditions are met. - Sentry Key Customer Learn Mode Announcement - The EMIC transducer will generate one short chime to confirm that an electronic Customer Learn mode message has been received over the CAN data bus to indicate that the Sentry Key REmote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) is prepared for programming additional sentry key transponders. This chime feature is only active on vehicles equipped with the optional Sentry Key system, and sold in a market where Customer Learn programming is an allowed feature. - Trans Overtemp Indicator Warning - On vehicles equipped with an automatic transmission only, the EMIC transducer will generate repetitive chimes at a slow rate when the transmission overtemp indicator is illuminated by the instrument cluster circuitry for a high or critical transmission fluid temperature condition. This chime will repeat each time the trans overtemp indicator is cycled from OFF to ON. - Turn Signal/Hazard Warning Flasher Emulation - The EMIC relay will generate repetitive clicks at a slow rate to emulate an electromechanical flasher when the turn signal or hazard warning system are operating. The EMIC relay will generate repetitive clicks at a fast rate to indicate that the right or left turn signals are operating with one or more bulbs ineffective. In either case, the clicks will continue until the turn signal and hazard warning systems are turned OFF. - Turn Signal On Warning - The EMIC transducer will generate repetitive chimes at a slow rate to indicate that a turn signal has been active continuously for 1.6 kilometers (1 mile) with the vehicle speed greater than 22 kilometers-per-hour (15 miles-per hour). Vehicles built for markets other than the United States and Canada have a revised distance threshold of 4 kilometers (2.49 miles) for this feature. The chime will continue until the turn signal input becomes inactive or until the electronic vehicle speed message indicates that the speed is less than 22 kilometers-per-hour (15 miles-per-hour), whichever occurs first. The hazard warning flashers will not activate this chime feature. - Warning Indicator Announcement - The EMIC transducer will generate one short chime each time the check gauges indicator is illuminated by the instrument cluster circuitry. The check gauges indicator may be illuminated when any critical engine or transmission systems are operating outside of their normal parameters. The instrument cluster monitors electronic messages received over the CAN data bus to determine when to illuminate the check gauges indicator. The EMIC provides chime service for all available features in the chime warning system. The EMIC relies upon its internal programming, numerous hard wired inputs, and electronic message inputs received from other modules over the CAN data bus network to provide the chime warning system features. The internal programming of the EMIC determines the priority of each chime request input that is received, as well as the rate and duration of each chime that is to be generated. The hard wired circuits between components related to the chime warning system may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the chime warning system or the electronic controls or communication between modules and other devices that provide some features of the chime warning system. The most reliable, efficient, and accurate means to diagnose the chime warning system or the electronic controls and communication related to chime warning system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Page 16055 Audible Warning Device: Testing and Inspection CHIME WARNING SYSTEM WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. The hard wired circuits between components related to the chime warning system may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the chime warning system or the electronic controls or communication between modules and other devices that provide some features of the chime warning system. The most reliable, efficient, and accurate means to diagnose the chime warning system or the electronic controls and communication related to chime warning system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Page 16056 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > Description Brake Warning Indicator: Description and Operation Description DESCRIPTION A brake indicator is standard equipment on all instrument clusters. This indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. The brake indicator consists of a stencil-like cutout of the word BRAKE and the International Control and Display Symbol icon for Brake Failure in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The brake indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > Description > Page 16061 Brake Warning Indicator: Description and Operation Operation OPERATION The brake indicator gives an indication to the vehicle operator when the parking brake is applied, when there are certain brake hydraulic system malfunctions as indicated by a low brake hydraulic fluid level condition, or when the brake fluid level switch is disconnected. The brake indicator can also give an indication when certain faults are detected in the Antilock Brake System (ABS). This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming, electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Controller Area Network (CAN) data bus, and a hard wired input from the park brake switch. The brake indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the brake indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the brake indicator is illuminated for about four seconds as a bulb test. The entire bulb test is a function of the CAB. - Brake Indicator Lamp-On Message - Each time the cluster receives an electronic brake indicator lamp-ON message from the CAB, the brake indicator will be illuminated. The CAB may also send lamp-ON messages as feedback during ABS diagnostic procedures. The indicator remains illuminated until the cluster receives a lamp-OFF message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Park Brake Switch Input - Each time the cluster detects ground on the park brake switch sense circuit (park brake switch closed = park brake applied or not fully released) while the ignition switch is in the ON position, the brake indicator flashes ON and OFF. The indicator continues to flash until the park brake switch sense input to the cluster is an open circuit (park brake switch open = park brake fully released), or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the instrument cluster is put through the actuator test, the brake indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The park brake switch on the park brake pedal mechanism provides a hard wired ground input to the instrument cluster circuitry through the park brake switch sense circuit whenever the park brake is applied or not fully released. The CAB continually monitors the ABS system circuits and sensors, including the brake fluid level switch on the brake master cylinder reservoir, to decide whether the system is in good operating condition. The CAB then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the CAB sends a lamp-ON message after the bulb test, it indicates that the CAB has detected a brake hydraulic system malfunction or that the ABS system has become ineffective. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. For further diagnosis of the brake indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. The hard wired park brake switch input to the instrument cluster may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. For proper diagnosis of the brake fluid level switch, the ABS, the CAB, the EMIC, the CAN data bus or the electronic communication related to brake indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > Page 16062 Brake Warning Indicator: Testing and Inspection BRAKE INDICATOR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. The hard wired park brake switch input to the EMIC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the Controller Antilock Brake (CAB), the Controller Area Network (CAN) data bus, or the electronic message inputs also used by the EMIC to provide brake indicator operation. The most reliable, efficient, and accurate means to diagnose the EMIC, the CAB, the CAN data bus or the electronic communication related to brake indicator operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Description and Operation > Description Check Gauges Lamp: Description and Operation Description DESCRIPTION A check gauges indicator is standard equipment on all instrument clusters. The check gauges indicator is located on the left side of the instrument cluster, to the left of the voltage gauge. The check gauges indicator consists of a stencil-like cutout of the words CHECK GAGES in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The check gauges indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Description and Operation > Description > Page 16067 Check Gauges Lamp: Description and Operation Operation OPERATION The check gauges indicator gives an indication to the vehicle operator when certain instrument cluster gauge readings reflect a condition requiring immediate attention. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Controller Area Network (CAN) data bus. The check gauges indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the check gauges indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the check gauges indicator is illuminated for about two seconds as a bulb test. - Engine Temperature High Message - Each time the cluster receives three consecutive electronic messages from the PCM or ECM indicating the engine coolant temperature is high, the check gauges indicator will be illuminated and a single chime is sounded. The indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the engine coolant temperature is not high, or until the ignition switch is turned to the OFF position, whichever occurs first. - Engine Oil Pressure Low Message - Each time the cluster receives three consecutive electronic messages from the PCM or ECM indicating the engine oil pressure is low, the check gauges indicator will be illuminated and a single chime is sounded. The indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the engine oil pressure is not low, or until the ignition switch is turned to the OFF position, whichever occurs first. The cluster will only turn the indicator ON in response to an engine oil pressure low message if the engine speed is greater than zero. - System Voltage Low (Charge Fail) Message - Each time the cluster receives three consecutive electronic messages from the PCM or ECM indicating the electrical system voltage is low (charge fail condition) or that the battery temperature sensor input is an open circuit, the check gauges indicator will be illuminated and a single chime is sounded. The indicator remains illuminated until the cluster receives a single message from the PCM or ECM indicating the electrical system voltage is not low, or until the ignition switch is turned to the OFF position, whichever occurs first. - System Voltage High Message - Each time the cluster receives three consecutive electronic messages from the PCM or ECM indicating the electrical system voltage is high, the check gauges indicator will be illuminated and a single chime is sounded. The indicator remains illuminated until the cluster receives a single message from the PCM or ECM indicating the electrical system voltage is not high, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the check gauges indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM (gasoline engine) or ECM (diesel engine) continually monitors the engine temperature, oil pressure and electrical system voltage, then sends the proper messages to the ElectroMechanical Instrument Cluster (EMIC). For proper diagnosis of the PCM, the ECM, the EMIC, the CAN data bus or the electronic communication related to check gauges indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Locations Cigarette Lighter: Locations Component ID: 193 Component : LIGHTER-CIGAR Connector: Name : LIGHTER-CIGAR Color : GRAY # of pins : 3 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F984 18PK/YL 2-3 GROUND Z736 18BK/YL Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Locations > Page 16071 Component Location - 44 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Locations > Page 16072 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16075 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16076 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16077 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16078 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16079 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16080 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16081 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16082 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16083 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16084 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16085 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16086 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16087 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16088 Cigarette Lighter: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16089 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16090 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16091 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16092 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16093 Cigarette Lighter: Connector Views Component ID: 193 Component : LIGHTER-CIGAR Connector: Name : LIGHTER-CIGAR Color : GRAY # of pins : 3 Pin Description Circuit 1 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F984 18PK/YL 2-3 GROUND Z736 18BK/YL Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16094 Component Location - 44 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16095 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16096 Cigarette Lighter: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-41-02 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16097 8w-41-03 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 16098 8w-41-04 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Description and Operation > Description Compass: Description and Operation Description DESCRIPTION NOTE: The Compass Mini-Trip Computer (CMTC) module is sometimes referred to as Electronic Overhead Module (EOM) for the purposes of scan tool and diagnostic information naming. Please treat the CMTC and EOM as one and the same when diagnosing the vehicle. The Compass Mini-Trip Computer (CMTC) is located in the overhead console and consists of the following components: - HomeLink(R) transceiver (3) - if equipped - Vacuum-Fluorescent Display (VFD) (6) - Push button function switches (1, 2, 3, 4 and 5) - Replaceable light bulbs to illuminate the push button function switches The CMTC contains a central processing unit and interfaces with other electronic modules in the vehicle on the Controller Area Network (CAN) data bus. The CAN data bus allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The individual components of the CMTC module are not serviced separately and if damaged or inoperative, must be replaced as a unit. The CMTC provides several electronic functions and features. Some of the functions and features that the CMTC supports and/or controls, include the following display options: - Compass and Temperature - provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. - Trip Odometer (ODO) - shows the distance travelled since the last trip computer reset. Average Fuel Economy (AVG ECO) - shows the average fuel economy since the last reset. Average fuel economy is a running average of the amount of fuel used and the distance the vehicle has traveled. When the fuel economy is reset, the display will momentarily blank. Then, the display will show the same value as before the rest. The reset value is based on a minimal amount of fuel used and the distance traveled from the previous drive cycle. The display may take several miles for this value to change dependent upon driving habits. - Distance To Empty (DTE) - shows the estimated distance that can be traveled with the fuel remaining in the tank. This estimated distance is determined by weighted average of the instantaneous and average fuel economy, according to the current fuel tank level. This is not resettable. Significant changes in driving style or vehicle loading will greatly affect the actual drivable distance of the vehicle, regardless of the DTE displayed value. When the DTE value is less than 30 miles estimated driving distance, the DTE display will change to an alternating test display of "LO" and "FUEL". This display will continue until the vehicle runs out of fuel. Adding a significant amount of fuel to the vehicle will turn off the "LO FUEL" text and a new DTE value will be displayed, based on the current values in the DTE calculation and the current fuel tank level. - Elapsed time (ET) - shows the accumulated ignition-on time since the last trip computer reset. - Blank screen - the compass mini-trip computer VFD is turned off or in Blank Screen Mode. COMPASS NOTE: If the compass functions, but accuracy is suspect, it may be necessary to perform a variance adjustment. This procedure allows the compass unit to accommodate variances in the earth's magnetic field strength, based on geographic location. While in the compass/temperature mode, the compass will display the direction in which the vehicle is pointed using the eight major compass headings (Examples: north is N, northeast is NE). The auto-calibrating compass unit requires no manual adjusting in normal use. The only calibration that may prove necessary is to drive the vehicle in one or two complete circles, on level ground, not exceeding 8 km/h (5 mph). This will reorient the compass unit to its vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Description and Operation > Description > Page 16103 The compass unit also will compensate for vehicle magnetism acquired during normal use. However, avoid placing anything magnetic directly on the roof of the vehicle. Magnetic mounts for an antenna, a repair order hat, or a funeral procession flag can exceed the compensating ability of the compass unit if placed on the roof panel. Magnetic bit drivers used on the fasteners that hold the overhead console assembly to the roof header can also affect compass operation. TEMPERATURE NOTE: The displayed temperature is not an instant reading of conditions, but an average temperature. It may take the temperature display several minutes to respond to a major temperature change, such as driving out of a heated garage into winter temperatures. The temperature displays the outside ambient temperature in whole degrees. The temperature display can be toggled from Fahrenheit to Celsius using the U.S./Metric push button. Displayed temperature reading stays in the temperature unit memory. When the ignition switch is turned to the On position, the temperature will display the memory temperature if the engine OFF time is less than 255 minutes. If the engine OFF time is more than 255 minutes, the temperature will display the actual temperature sensed by the ambient temperature sensor. The temperature display update interval varies with the vehicle speed. The temperature function is supported by an ambient temperature sensor. This sensor is mounted outside the passenger compartment near the front and center of the vehicle, and is hard wired to the Front Control Module (FCM). The instrument cluster, also known as the Cab Compartment Node (CCN) averages and filters the ambient temperature signal and supplies it to other modules on the CAN data bus. Data input for all other compass mini-trip computer functions, including VFD dimming level, is received through CAN data bus messages. The maximum temperature displayed is 66° C (140° F). It could take several miles for the accurate temperature to be displayed as the CCN filters out heat from the engine compartment. The CMTC uses its internal programming and all of these inputs to calculate and display the requested data. If the data displayed is incorrect, perform the self-diagnostic tests. If these tests prove inconclusive, the use of a scan tool and the proper Diagnostic Procedures Information are recommended for further testing of the CMTC and the CAN data bus. NOTE: The CMTC will display min and max temperatures of -40° C (-40° F) and 66° C (140° F). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Description and Operation > Description > Page 16104 Compass: Description and Operation Operation OPERATION The Compass Mini-Trip Computer (CMTC) only operates with the ignition switch in the On position and the Ignition Off Draw (IOD) fuse functioning and in place. When the ignition switch is turned to the On position, all of the segments in the CMTC Vacuum-Fluorescent Display (VFD) will be turned off for one second, then the display will return to the last function being displayed before the ignition was turned to the Off position. With the ignition switch in the On position, momentarily depressing and releasing the STEP push button (4) will cause the CMTC to change its mode of operation. Momentarily depressing and releasing the U.S./M push button (1) will cause the unit to toggle between U.S. and Metric measurements. Momentarily depressing and releasing the C/T (compass/temperature) push button (5) will cause the CMTC to return to the compass/temperature display mode from any other mode. Pressing the RESET push button (2) for more than one second with the ignition switch in the On position will reset the following CMTC functions: - Average Fuel Economy (AVG ECO) - Trip Odometer (ODO) - Elapsed Time (ET) However, the reset will only occur if the function currently displayed is a function that can be reset. If the RESET push button is pressed twice within two seconds while in any of the three resettable functions (AVG ECO, ODO, ET), all three of these functions will be reset. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Description and Operation > Page 16105 Compass: Testing and Inspection COMPASS MINI-TRIP COMPUTER NOTE: The temperature, fuel economy, distance to empty and trip odometer are calculated in the Cab Compartment Node (CCN) and transferred to the Compass Mini-Trip Computer (CMTC) for display. If the CMTC and Vacuum Fluorescent Display (VFD) test OK, testing of the CCN and Controller Area Network (CAN) data bus circuit may be necessary. Refer to the proper Diagnostic Procedures Information to test the CCN and CAN data bus circuit. If the problem with the CMTC is an inaccurate or scrambled display, refer to SELF- DIAGNOSTIC TEST. If the problem with the CMTC is incorrect Vacuum Fluorescent Display (VFD) dimming levels, use a scan tool and the proper Diagnostic Procedures Information to test for the correct dimming message inputs being received from the Cab Compartment Node (CCN) or Front Control Module (FCM) over the Controller Area Network (CAN) data bus circuit. If the problem is a no-display condition, use the following procedure. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the overhead console from the headliner. 2. Inspect the Ignition Off Draw (IOD) fuse in the Totally Integrated Power Module (TIPM). If the IOD fuse is OK and in place, go to STEP 3. If not OK, repair the open IOD fuse circuit as required. 3. Check for battery voltage at the overhead console electrical connector. If OK, go to STEP 4. If not OK, Check for battery voltage at the appropriate B(+) fuse in the Totally Integrated Power Module (TIPM), repair the open fused B(+) circuit as required. 4. Turn the ignition switch to the On position. Check the fused ignition switch output circuit(s) at the overhead console electrical connector. If OK, go to STEP 5. If not OK, repair the open or shorted circuit as required. 5. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Check for continuity between the ground circuit cavity of the overhead console electrical connector and a good ground. There should be continuity. If OK, refer to SELF- DIAGNOSTIC TEST for further diagnosis of the CMTC module and the CAN data bus circuit. If not OK, repair the open ground circuit as required. SELF- DIAGNOSTIC TEST NOTE: The CMTC self - test can also be performed using a scan tool. Navigate to the Auto Self Test screen under System Tests of the scan tool and initiate the CMTC self - test. A self-diagnostic test is used to determine that the CMTC is operating properly electrically. Initiate the self-diagnostic test as follows: 1. With the ignition switch in the Off position, simultaneously depress and hold the STEP and RESET buttons while rotating the ignition switch to the Run/On position. 2. Continue to hold both buttons depressed until the CMTC enters the display segment test. In this test, all of the Vacuum Fluorescent Display (VFD) segments are lighted while the CMTC performs the following checks: Non-Volatile Memory Status (NVM) - RAM Status - ROM Status - ASIC Communication Status - Compass Status - DC Status - CAN Data Bus Communications Status NOTE: If the CMTC module is equipped with the Universal Transmitter (also known as HomeLink(R)), the module also checks "HomeLink(R) Communication Test Status". 3. Following completion of these tests, the CMTC will display one of two messages: "FAIL" or "PASS." Press the RESET or STEP button to exit and enter normal mode. Respond to these test results as follows: If no test result message is displayed, but CMTC operation is still improper, the use of a scan tool and the proper Diagnostic Procedures Information are required for further diagnosis. - GIf the "FAIL" message is displayed, the CMTC is inoperative and must be replaced. - If the "PASS" message is displayed, the CMTC is OK, no faults are present. - If any VFD segment does not light during the display segment test, the CMTC is inoperative and must be replaced. If the first seven tests pass, the CMTC shall verify that all the required CAN bus messages are present on the CAN bus. If all required messages are Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Description and Operation > Page 16106 present on the CAN bus, the CMTC will automatically return to normal operation after sixty seconds. The CMTC can also be returned to normal operation any time during the test by pressing the STEP, CT, RESET or US/M buttons. NOTE: Pressing the STEP or RESET buttons during any portion of the CMTC Self - Diagnostic Test Procedure will cause the CMTC to exit diagnostics and return to compass/temperature mode. NOTE: If the compass functions, but accuracy is suspect, it may be necessary to perform a variance adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. NOTE: If the compass reading has blanked out, and only "CAL" appears in the display, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle. Check for stored Diagnostic Trouble Codes (DTCs) and follow the proper Diagnostic Procedures Information as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Manual Compass Calibration Compass: Adjustments Manual Compass Calibration MANUAL COMPASS CALIBRATION CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the overhead console. Do not use magnetic tools when servicing the overhead console. NOTE: Whenever the compass is calibrated manually, the variance number must also be reset. The electronic compass unit features a self-calibrating design, which simplifies the calibration procedure. This feature automatically updates the compass calibration while the vehicle is being driven. This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use. If the compass readings appear to be erratic or out of calibration, perform the following calibration procedure. Also, new service replacement Compass Mini-Trip Computer (CMTC) modules must have their compass calibrated using this procedure. Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. Calibrate the compass manually as follows: 1. Turn the ignition switch to the On position. If the compass/temperature data is not currently being displayed, momentarily depress and release the C/T push button (5) to return to the compass/temperature display. 2. Depress and hold the RESET push button (2). Hold the push button down until "CAL" appears in the display. This takes about ten seconds. 3. Slowly drive the vehicle on a level surface, away from large metal objects and power lines, through one or two complete circles not exceeding 8 km/h (5 mph). The "CAL" message will disappear from the display to indicate that the compass is now calibrated. NOTE: A blank compass display indicates that vehicle degaussing (demagnetizing) may be necessary. NOTE: If the "CAL" message remains in the display, either there is excessive magnetism near the compass, or the CMTC is inoperative. Attempt the calibration procedure at least one more time before performing CMTC diagnosis. NOTE: If the wrong direction is still indicated in the compass display, the area selected for calibration may be too close to a strong magnetic field. Repeat the calibration procedure in another location. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Manual Compass Calibration > Page 16109 Compass: Adjustments Compass Variance Adjustment COMPASS VARIANCE ADJUSTMENT Compass variance, also known as magnetic declination, is the difference in angle between magnetic north and true geographic north. In some geographic locations, the difference between magnetic and geographic north is great enough to cause the compass to give false readings. If this problem occurs, the compass variance must be set. NOTE: If the vehicle is taken on long trips into a new variance zone the compass function may be effected. Compass variance may need to be adjusted to the new zone number to function properly. NOTE: The default for the compass variance from the factory is 8. To set the compass variance: 1. Using the Variance Settings Map, find your geographic location and note the zone number. 2. Turn the ignition switch to the On/Run position. If the compass/temperature data is not currently being displayed, momentarily depress and release the C/T push button (5) to return to the compass/temperature display. 3. Press and hold the RESET push button (2) down for approximately five seconds. The last variance zone number will be displayed. 4. Momentarily depress and release the STEP push button (4) to toggle through the zone numbers (1-15), until the zone number for your geographic location appears in the display. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Manual Compass Calibration > Page 16110 5. Momentarily depress and release the RESET push button (2) to enter the displayed zone number into the compass unit memory. 6. Confirm that the correct directions are now indicated by the compass. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Procedures Compass: Procedures COMPASS DEMAGNETIZING A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the overhead console forward mounting screw and the roof panel above the overhead console. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 millimeters (0.25 inch) beyond the tip of the probe. To demagnetize the roof panel and the overhead console forward mounting screw, proceed as follows: 1. Be certain that the ignition switch is in the Off position, before you begin the demagnetizing procedure. 2. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 3. Slowly approach the head of the overhead console forward mounting screw with the degaussing tool connected. 4. Contact the head of the screw with the plastic coated tip of the degaussing tool for about two seconds. 5. With the degaussing tool still energized, slowly back it away from the screw. When the tip of the tool is at least 61 centimeters (2 feet) from the screw head, disconnect the tool. 6. Place a piece of paper approximately 22 by 28 centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header. The purpose of the paper is to protect the roof panel from scratches, and to define the area to be demagnetized. 7. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 8. Slowly approach the center line of the roof panel at the windshield header, with the degaussing tool connected. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Procedures > Page 16113 9. Contact the roof panel with the plastic coated tip of the degaussing tool. Be sure that the template is in place to avoid scratching the roof panel. Using a slow, back-and-forth sweeping motion, and allowing 13 millimeters (0.50 inch) between passes, move the tool at least 11 centimeters (4 inches) to each side of the roof center line, and 28 centimeters (11 inches) back from the windshield header. 10. With the degaussing tool still energized, slowly back it away from the roof panel. When the tip of the tool is at least 61 centimeters (2 feet) from the roof panel, disconnect the tool. 11. Calibrate the compass and adjust the compass variance. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Procedures > Page 16114 Compass: Removal and Replacement Compass Mini - Trip Computer COMPASS MINI - TRIP COMPUTER 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console (3) from the headliner. 3. Remove the screws (1) that secure the Compass Mini - Trip Computer (CMTC) (4) to the overhead console housing (3). 4. Remove the CMTC (4) from the overhead console housing (3). Bulb - CMTC Control BULB - CMTC CONTROL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: There are provisions for up to three bulb/bulb holder units on the Compass Mini-Trip Computer (CMTC) circuit board. The two outboard bulbs illuminate the CMTC push buttons, while the center bulb illuminates the optional universal transmitter push buttons. Therefore, the center bulb location is only populated on vehicles equipped with the optional universal transmitter. 1. Disconnect and isolate the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Procedures > Page 16115 2. Remove the overhead console (1) from the headliner. 3. Use a small thin-bladed screwdriver to rotate the bulb holder (3) counterclockwise about 30 degrees to unlock it from the keyed opening in the Compass Mini-Trip Computer (CMTC) unit (2) circuit board. 4. Pull the bulb holder and bulb straight out of the circuit board. Compass Mini - Trip Computer COMPASS MINI - TRIP COMPUTER NOTE: If a new Compass Mini - Trip Computer has been installed, the compass will have to be calibrated and the variance set. 1. Position the CMTC (4) onto the overhead console housing (3). 2. Install the screws (1) that secure the CMTC (4) to the overhead console housing (3). Tighten the screws to 2 Nm (20 in. lbs.). 3. Install the overhead console (3) onto the headliner. 4. Reconnect the battery negative cable. Bulb - CMTC Control BULB - CMTC CONTROL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: There are provisions for up to three bulb/bulb holder units on the Compass Mini-Trip Computer (CMTC) circuit board. The two outboard bulbs illuminate the CMTC push buttons, while the center bulb illuminates the optional universal transmitter push buttons. Therefore, the center bulb location is only populated on vehicles equipped with the optional universal transmitter. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Procedures > Page 16116 1. Align the bulb holder and bulb (3) with the keyed opening in the circuit board of the Compass Mini-Trip Computer (CMTC) (2). 2. Insert the bulb holder and bulb straight into the circuit board until the bulb holder is firmly seated. 3. Using a small thin-bladed screwdriver, rotate the bulb holder clockwise about 30 degrees on the circuit board to lock it into place. 4. Reinstall the overhead console (1) onto the headliner. 5. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cruise Control Indicator Lamp > Component Information > Description and Operation > Description Cruise Control Indicator Lamp: Description and Operation Description DESCRIPTION A cruise indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional speed control system, this indicator is electronically disabled. The cruise indicator is located on the left side of the cluster, to the left of the fuel gauge. The cruise indicator consists of a stencil-like cutout of the word CRUISE in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A green Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in green through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON the illumination intensity of the cruise indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The cruise indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cruise Control Indicator Lamp > Component Information > Description and Operation > Description > Page 16121 Cruise Control Indicator Lamp: Description and Operation Operation OPERATION The cruise indicator gives an indication to the vehicle operator when the speed control system is ON, regardless of whether the speed control is engaged. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The cruise indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the cruise indicator for the following reasons: - Cruise Indicator Lamp-On Message - Each time the cluster receives an electronic cruise indicator lamp-ON message from the PCM indicating the speed control system is ON, the cruise indicator is illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the cruise indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the speed control switches to determine the proper outputs to the speed control servo. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For proper diagnosis of the speed control system, the PCM, the EMIC, the CAN data bus or the electronic communication related to cruise indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation Air Bag(s) Arming and Disarming: Technical Service Bulletins Air Bag System - Passenger Air Bag Deactivation NUMBER: 08-001-07 REV. B GROUP: Electrical DATE: May 16, 2007 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED. THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION. DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION. SUBJECT: Passenger Air Bag Deactivation MODELS: 2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 0300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakoka 2006 - 2007 (DR) Ram Truck 2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 16127 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet. NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States. PARTS REQUIRED: POLICY: Information Only Disclaimer: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 16128 This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Description and Operation > Description Door/Trunk Ajar Indicator/Lamp: Description and Operation Description DESCRIPTION A door ajar indicator is standard equipment on all instrument clusters. This indicator is located on the left side of the instrument cluster, to the left of the fuel gauge. The door ajar indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Door(s) Ajar in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The door ajar indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Description and Operation > Description > Page 16133 Door/Trunk Ajar Indicator/Lamp: Description and Operation Operation OPERATION The door ajar indicator gives an indication to the vehicle operator that one or more of the passenger compartment doors may be open or not completely latched. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and hard wired inputs received by the cluster from the door ajar switches located in each door latch unit. The door ajar indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will allow this indicator to operate whenever the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the door ajar indicator for the following reasons: - Door Ajar Switch Input - Each time the cluster detects ground on any one of the door ajar switch sense circuits (door ajar switch closed = door is open or not completely latched) the door ajar indicator will be illuminated. The indicator remains illuminated until all of the door ajar switch sense inputs to the cluster are an open circuit (door ajar switch open = door fully closed), until the cluster has completed an interior lamps load shed ( about five minutes), or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the door ajar indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The ElectroMechanical Instrument Cluster (EMIC) continually monitors the door ajar switches to determine the status of the doors. The hard wired door ajar switches and circuits related to door ajar indicator operation may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Description and Operation > Description Door Switch: Description and Operation Description DESCRIPTION This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if ineffective or damaged, the door latch unit must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Description and Operation > Description > Page 16138 Door Switch: Description and Operation Operation OPERATION The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper electronic door ajar switch status messages to other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. The door ajar switches as well as the hard wired inputs and outputs of the switches may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 16143 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 16144 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 16145 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 16146 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 16147 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 16148 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 16149 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 16150 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 16151 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 16152 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 16153 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 16154 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 16155 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 16156 Driver/Vehicle Information Display: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 16157 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 16158 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 16159 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 16160 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 16161 Driver/Vehicle Information Display: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-49-02 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 16162 Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Description Driver/Vehicle Information Display: Description and Operation Description DESCRIPTION NOTE: The Electronic Vehicle Information Center (EVIC) module is sometimes referred to as Electronic Overhead Module (EOM) for the purposes of scan tool and diagnostic information naming. Please treat the EVIC and EOM as one and the same when diagnosing the vehicle. The Electronic Vehicle Information Center (EVIC) is located in the overhead console and consists of the following components: - HomeLink(R) transceiver (3) - if equipped - Vacuum-Fluorescent Display (VFD) (6) - Push button function switches (1, 2, 3, 4 and 5) - Replaceable light bulbs to illuminate the push button function switches This system conveniently allows the driver to select a variety of useful information by pressing the function buttons. The EVIC displays information related to the following: - System Status - Vehicle information warning message displays - Tire Pressure Monitor System - If Equipped - Personal Settings (customer programmable features) - Compass display - Outside temperature display - Trip computer functions The EVIC system is comprised of several different components. Those components are: - Instrument Cluster (also known as Cab Compartment Node (CCN)) - Ambient Temperature Sensor - EVIC Module - Controller Area Network (CAN) Data Bus circuit The individual components of the EVIC module are not serviced separately and if damaged or inoperative, must be replaced as a unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Description > Page 16165 Driver/Vehicle Information Display: Description and Operation Operation OPERATION The Electronic Vehicle Information Center (EVIC) uses both non-switched and ignition switched sources of battery current so that some of its features remain operational at any time, while others may only operate with the ignition switch in the On position. When the ignition switch is turned to the On position, the EVIC display will return to the last function being displayed before the ignition was turned to the Off position. The EVIC system is comprised of several different components that communicate over the Controller Area Network (CAN) Data Bus. If the system is inoperative a scan tool and the appropriate diagnostic information must be used to diagnose the system. The EVIC push buttons are used to operate the different functions of the EVIC system. Pressing and releasing the MENU button (1) will change the mode displayed to one of the Personal Settings. The STEP button (2) is used to make a selection from the Personal Settings displayed at that time. Pressing and releasing the C/T (compass/temperature) button (5) will cause the EVIC to return to the compass/temperature/trip computer display mode from any other mode. From the compass/temperature/trip computer display mode the STEP button (2) is used to scroll through and make selections in the Trip Functions. Pressing and releasing the RESET button (4) resets the trip computer screen displayed at that time. EVIC DISPLAY MODES SYSTEM STATUS MODE Displays warnings and user interaction messages. Critical text warnings will be displayed until the failure is corrected. Non-critical text warnings will be displayed for 60 seconds. The driver can scroll to view multiple messages by using the STEP button. When the appropriate conditions exist, the EVIC displays the following messages: - TURN SIGNALS ON (with a continuous warning chime) - RKE BATTERY LOW (with a single chime) - PERSONAL SETTINGS NOT AVAILABLE - Vehicle Not in Park - LEFT/RIGHT FRONT DOOR AJAR (one or more, with a single chime if speed is above 1 mph) - LEFT/RIGHT REAR DOOR AJAR (one or more, with a single chime if speed is above 1 mph) - DOOR(S) AJAR (with a single chime if vehicle is in motion) - LOW WASHER FLUID (with a single chime) - SERVICE PARK ASSIST SYSTEM (with a single chime) - OIL CHANGE REQUIRED (with single chime) - LEFT FRONT TURN LAMP OUT - RIGHT FRONT TURN LAMP OUT - LEFT REAR TURN LAMP OUT - RIGHT REAR TURN LAMP OUT - SERVICE PARK ASSIST SYSTEM - CATALYST FULL SEE OWNER MANUAL - CATALYST STAT lllll 99% - CATALYST FULL SERVICE REQUIRED - SERVICE AIR FILTER - SERVICE CCV FILTER - COOLANT LOW - ESP SYSTEM DEACTIVATED Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Description > Page 16166 - AUTO HIGH BEAMS ON - AUTO HIGH BEAMS OFF PERSONAL SETTINGS MODE (CUSTOMER PROGRAMMABLE FEATURES) Allows the driver to set and recall features when the transmission is in Park by pressing and releasing the MENU button until Personal Settings is displayed in the EVIC. If the transmission is not in PARK the EVIC will display NOT AVAILABLE and VEHICLE NOT IN PARK. The following personal settings can be set and recalled by pressing the STEP button: - "LANGUAGE" - When in this display you may select one of three languages for all display nomenclature, including the trip functions. Press the RESET button while in this display to select English, Espanol, or Francais. Then, as you continue, the information will display in the selected language. - "AUTO DOOR LOCKS > YES" - When ON is selected, all doors will lock automatically when the vehicle reaches a speed of 15 mph (24 km/h). To make your selection, press and release the RESET button until "ON" or "OFF" appears. - "AUTO UNLOCK ON EXIT > YES" - When ON is selected, all doors will unlock when the vehicle is stopped and the transmission is in the P (Park) or N (Neutral) position and the driver's door is opened. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - "RKE UNLOCK DRV DR 1st" - When DRV DR 1st is selected, only the driver's door will unlock on the first press of the remote keyless entry unlock button. When Driver Door 1st Press is selected, you must press of the remote keyless entry unlock button twice to unlock the passenger's doors. To make your selection, press and release the RESET button until "DRV DR 1st " appears. - "RKE UNLOCK ALL DR 1ST" - When All ALL DR 1ST is selected, all of the doors will unlock on the first press of the remote keyless entry unlock button. To make your selection, press and release the RESET button until "All DR 1st" appears. - "SOUND HORN W/LOCK > YES" - When ON is selected, a short horn sound will occur when the remote keyless entry "Lock" button is pressed. This feature may be selected with or without the flash lights on lock/unlock feature. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - "FLASH LIGHTS w/LOCK > YES" - When ON is selected, the front and rear turn signals will flash when the doors are locked or unlocked with the remote keyless entry transmitter. This feature may be selected with or without the sound horn on lock feature selected. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - "HEAD LAMP OFF DELAY > 0 SEC" - When this feature is selected, the driver can choose to have the headlights remain on for 0, 30, 60, or 90 seconds when exiting the vehicle. To make your selection, press and release the RESET button until "0," "30," "60," or "90" appears. - "KEY OFF POWER DELAY > OFF" - When this feature is selected, the power window switches, radio, hands-free system (if equipped), DVD video system (if equipped) and power outlets will remain active for up to 60 minutes after the ignition switch is turned off. Opening a vehicle door will cancel this feature. To make your selection, press and release the RESET button until "Off," "45 sec.," "5 min.," "10 min." appears. - "ILLUMINATED APRCH > OFF" - When this feature is selected, the headlights will activate and remain on for up to 90 seconds when the doors are unlocked with the remote keyless entry transmitter. To make your selection, press and release the RESET button until "OFF," "30 sec.," "60 sec.," or "90 sec." appears. - "UNIT IN > US/METRIC" - The EVIC, odometer can be changed between English and Metric units of measure. To make your selection, press and release the RESET button until "US" or "METRIC" appears. - "COMPASS VARIANCE > 1" - Press the RESET button to change the compass variance setting. - "COMPASS CALIBRATE > YES" - Press the RESET button to calibrate the compass. COMPASS/TEMPERATURE/TRIP COMPUTER MODE This display provides the outside temperature, one of the eight compass headings to indicate the direction the vehicle is facing, and vehicle trip information. The compass and temperature display is the normal display. When the C/T button is pressed the EVIC returns to the compass/temperature display from all other functions. The trip computer function will be displayed if the STEP button is pressed from the Compass/Temperature display mode. The trip computer displays the following information: - TRIP - Shows the total distance traveled since the last reset. To reset the TRIP function, press and hold the RESET button. - ELAPSED TIME - Shows the total elapsed time of travel since the last reset. Elapsed time will increment when the ignition switch is in the ON/RUN or START positions. - UNIT IN US/METRIC - Press the RESET button to toggle between US and METRIC. - AVG. MPG - Shows the average fuel economy since the last reset. When the fuel economy is reset, the display will show dashes for two seconds. Then the history information will be erased, and the averaging will continue from the last fuel average reading before the reset. (Example: If your Electronic Vehicle Information Center (EVIC) displays 18 AVG. MPG and the RESET button is pressed, the previous averaging history will be erased and the display will return to the 18 AVG. MPG, not to 0 AVG. MPG). The display may take several miles for the value to change dependent upon driving habits. - MI TO EMPTY (Distance To Empty) - Shows the estimated distance that can be traveled with the fuel remaining in the tank. This estimated distance is determined by a weighted average of fuel economy, according to the current fuel tank level. Distance MI TO EMPTY cannot be reset through the RESET button. When the DTE value is less than 30 miles (48 km) estimated driving distance, the DTE display will change to a text display of "LOW FUEL." This display will continue until the vehicle runs out of fuel. Adding a significant amount of fuel to the vehicle will turn off the "LOW FUEL" text and a new DTE value will display. UNIVERSAL GARAGE DOOR (HOMELINK(R)) TRANSCEIVER Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Description > Page 16167 The EVIC features a driver-interactive display which includes HomeLink(R) system messages. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Page 16168 Driver/Vehicle Information Display: Testing and Inspection ELECTRONIC VEHICLE INFORMATION CENTER The Electronic Vehicle Information Center (EVIC) data is obtained from several components on the Controller Area Network (CAN) Data Bus circuit. The EVIC will not function properly if the bus messages from any of these components is not received. If no EVIC data is displayed, check the CAN Data Bus circuit communications, the Instrument Cluster (also known as Cab Compartment Node (CCN)) functions and the Totally Integrated Power Module (TIPM). If the problem with the EVIC is an inaccurate or scrambled display, refer to SELF- DIAGNOSTIC TEST. If the problem with the EVIC is incorrect Vacuum Fluorescent Display (VFD) dimming levels, use a scan tool and the proper Diagnostic Procedures Information to test for the correct dimming message inputs being received from the CCN or TIPM over the CAN data bus circuit. If the problem is a no-display condition, use the following procedure. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the overhead console from the headliner. 2. Inspect the Ignition Off Draw (IOD) fuse in the TIPM. If the IOD fuse is OK and in place, go to STEP 3. If not OK, repair the open IOD fuse circuit as required. 3. Check for battery voltage at the overhead console electrical connector. If OK, go to STEP 4. If not OK, Check for battery voltage at the appropriate B(+) fuse in the TIPM, repair the open fused B(+) circuit as required. 4. Turn the ignition switch to the On position. Check the fused ignition switch output circuit(s) at the overhead console electrical connector. If OK, go to STEP 5. If not OK, repair the open or shorted circuit as required. 5. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Check for continuity between the ground circuit cavity of the overhead console electrical connector and a good ground. There should be continuity. If OK, refer to SELF- DIAGNOSTIC TEST for further diagnosis of the EVIC module and the CAN data bus circuit. If not OK, repair the open ground circuit as required. SELF- DIAGNOSTIC TEST NOTE: The EVIC self - test can also be performed using a scan tool. Navigate to the Auto Self Test screen under System Tests of the scan tool and initiate the EVIC self - test. A self-diagnostic test is used to determine that the EVIC is operating properly electrically. Initiate the self-diagnostic test as follows: 1. With the ignition switch in the Off position, simultaneously depress and hold the STEP and RESET buttons while rotating the ignition switch to the Run/On position. 2. Continue to hold both buttons depressed until the EVIC enters the display segment test. In this test, all of the Vacuum Fluorescent Display (VFD) segments are lighted while the EVIC performs the following checks: - Non-Volatile Memory Status (NVM) - RAM Status - ROM Status - ASIC Communication Status - Compass Status - DC Status - CAN Data Bus Communications Status NOTE: If the EVIC module is equipped with the Universal Transmitter (also known as HomeLink(R)), the module also checks "HomeLink(R) Communication Test Status". 3. Following completion of these tests, the EVIC will display one of two messages: "Self Test: FAIL" or "Self Test: PASS." In addition to the FAIL/PASS message the EVIC will display the current software version (SW V xx.xx.xxx) below the FAIL/PASS info. Press the RESET or STEP button to exit and enter normal mode. Respond to these test results as follows: - If no test result message is displayed, but EVIC operation is still improper, the use of a scan tool and the proper Diagnostic Procedures Information are required for further diagnosis. - If the "Self Test: FAIL" message is displayed, the EVIC is inoperative and must be replaced. - If the "Self Test: PASS" message is displayed, the EVIC is OK, no faults are present. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Page 16169 - If any VFD segment does not light during the display segment test, the EVIC is inoperative and must be replaced. If the first seven tests pass, the EVIC shall verify that all the required CAN bus messages are present on the CAN bus. If all required messages are present on the CAN bus, the EVIC will automatically return to normal operation after sixty seconds. The EVIC can also be returned to normal operation any time during the test by pressing the STEP, C/T, RESET or US/M buttons. NOTE: Pressing the STEP or RESET buttons during any portion of the EVIC Self - Diagnostic Test Procedure will cause the EVIC to exit diagnostics and return to compass/temperature mode. NOTE: If the compass functions, but accuracy is suspect, it may be necessary to perform a variance adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. NOTE: If the compass reading has blanked out, and only "CAL" appears in the display, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle. Check for stored Diagnostic Trouble Codes (DTCs) and follow the proper Diagnostic Procedures Information as needed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Adjustments > Manual Compass Calibration Driver/Vehicle Information Display: Adjustments Manual Compass Calibration MANUAL COMPASS CALIBRATION CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the overhead console. Do not use magnetic tools when servicing the overhead console. NOTE: Whenever the compass is calibrated manually, the variance number must also be reset. The electronic compass unit features a self-calibrating design, which simplifies the calibration procedure. This feature automatically updates the compass calibration while the vehicle is being driven. This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use. If the compass readings appear to be erratic or the Electronic Vehicle Information Center (EVIC) displays "CAL", perform the following manual calibration procedure. Also, any time EVIC service replacement components are installed, they must be calibrated using this procedure. Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. Calibrate the compass manually as follows: 1. Turn the ignition switch to the On/Run position. Press and release the MENU push button (1) until "Personal Settings" is displayed. 2. Press the STEP push button (4) until "Calibrate Compass YES" is displayed. 3. Momentarily depress and release the RESET push button (2) to initiate the calibration procedure. The message "CAL will appear in the Compass/Temperature display. 4. Slowly drive the vehicle on a level surface, away from large metal objects and power lines, through one or two complete circles not exceeding 8 km/h (5 mph). The "CAL" message will disappear from the display to indicate that the compass is now calibrated. NOTE: A blank compass display indicates that vehicle degaussing (demagnetizing) may be necessary. NOTE: If the "CAL" message remains in the display, either there is excessive magnetism near the compass, or the EVIC is inoperative. Attempt the calibration procedure at least one more time before performing EVIC diagnosis. NOTE: If the wrong direction is still indicated in the compass display, the area selected for calibration may be too close to a strong magnetic field. Repeat the manual calibration procedure in another location. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Adjustments > Manual Compass Calibration > Page 16172 Driver/Vehicle Information Display: Adjustments Compass Variance Adjustment COMPASS VARIANCE ADJUSTMENT Compass variance, also known as magnetic declination, is the difference in angle between magnetic north and true geographic north. In some geographic locations, the difference between magnetic and geographic north is great enough to cause the compass to give false readings. If this problem occurs, the compass variance must be set. NOTE: If the vehicle is taken on long trips into a new variance zone the compass function may be effected. Compass variance may need to be adjusted to the new zone number to function properly. NOTE: The default for the compass variance from the factory is 8. To set the compass variance: 1. Using the Variance Settings Map, find your geographic location and note the zone number. 2. Turn the ignition switch to the On/Run position. Press and release the MENU push button (1) until "Personal Settings" is displayed. 3. Press the STEP push button (4) until "Compass Variance" is displayed. 4. Momentarily depress and release the RESET push button (2) to toggle through the zone numbers (1-15), until the zone number for your geographic location appears in the display. 5. Momentarily depress and release the C/T push button (5) to enter the displayed zone number into the compass unit memory. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Adjustments > Manual Compass Calibration > Page 16173 6. Confirm that the correct directions are now indicated by the compass. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures Driver/Vehicle Information Display: Procedures COMPASS DEMAGNETIZING A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the overhead console forward mounting screw and the roof panel above the overhead console. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 millimeters (0.25 inch) beyond the tip of the probe. To demagnetize the roof panel and the overhead console forward mounting screw, proceed as follows: 1. Be certain that the ignition switch is in the Off position, before you begin the demagnetizing procedure. 2. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 3. Slowly approach the head of the overhead console forward mounting screw with the degaussing tool connected. 4. Contact the head of the screw with the plastic coated tip of the degaussing tool for about two seconds. 5. With the degaussing tool still energized, slowly back it away from the screw. When the tip of the tool is at least 61 centimeters (2 feet) from the screw head, disconnect the tool. To demagnetize the roof panel proceed as follows: 6. Place a piece of paper approximately 22 by 28 centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header. The purpose of the paper is to protect the roof panel from scratches, and to define the area to be demagnetized. 7. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 16176 8. Slowly approach the center line of the roof panel at the windshield header, with the degaussing tool connected. 9. Contact the roof panel with the plastic coated tip of the degaussing tool. Be sure that the template is in place to avoid scratching the roof panel. Using a slow, back-and-forth sweeping motion, and allowing 13 millimeters (0.50 inch) between passes, move the tool at least 11 centimeters (4 inches) to each side of the roof center line, and 28 centimeters (11 inches) back from the windshield header. 10. With the degaussing tool still energized, slowly back it away from the roof panel. When the tip of the tool is at least 61 centimeters (2 feet) from the roof panel, disconnect the tool. 11. Calibrate the compass and adjust the compass variance. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 16177 Driver/Vehicle Information Display: Removal and Replacement Electronic Vehicle Information Center ELECTRONIC VEHICLE INFORMATION CENTER 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console (3) from the headliner. 3. Remove the screws (2) that secure the Electronic Vehicle Information Center (EVIC) (3) to the overhead console housing (1). 4. Remove the EVIC (3) from the overhead console housing (1). Bulb - EVIC Control BULB - EVIC CONTROL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: There are provisions for up to four bulb/bulb holder units on the Electronic Vehicle Information Center (EVIC) circuit board. The two outboard bulbs illuminate the EVIC push buttons, while the two center bulbs illuminate the optional universal transmitter push buttons. Therefore, the center bulb locations are only populated on vehicles equipped with the optional universal transmitter. 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console (1) from the headliner. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 16178 3. Use a small thin-bladed screwdriver to rotate the bulb holder (3) counterclockwise about 30 degrees to unlock it from the keyed opening in the Electronic Vehicle Information Center (EVIC) unit (2) circuit board. 4. Pull the bulb holder and bulb straight out of the circuit board. Electronic Vehicle Information Center ELECTRONIC VEHICLE INFORMATION CENTER NOTE: If a new Electronic Vehicle Information Center (EVIC) has been installed, the compass will have to be calibrated and the variance set. 1. Position the EVIC (3) onto the overhead console housing (1). 2. Install the screws (2) that secure the EVIC (3) to the overhead console housing (1). Tighten the screws to 2 Nm (20 in. lbs.). 3. Install the overhead console (1) onto the headliner. 4. Reconnect the battery negative cable. Bulb - EVIC Control BULB - EVIC CONTROL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: There are provisions for up to four bulb/bulb holder units on the Electronic Vehicle Information Center (EVIC) circuit board. The two outboard bulbs illuminate the EVIC push buttons, while the two center bulbs illuminate the optional universal transmitter push buttons. Therefore, the center bulb locations are only populated on vehicles equipped with the optional universal transmitter. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 16179 1. Align the bulb holder and bulb (3) with the keyed opening in the circuit board of the Electronic Vehicle Information Center (EVIC) (2). 2. Insert the bulb holder and bulb straight into the circuit board until the bulb holder is firmly seated. 3. Using a small thin-bladed screwdriver, rotate the bulb holder clockwise about 30 degrees on the circuit board to lock it into place. 4. Reinstall the overhead console (1) onto the headliner. 5. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Electronic Throttle Control Indicator > Component Information > Description and Operation > Description Electronic Throttle Control Indicator: Description and Operation Description DESCRIPTION An Electronic Throttle Control (ETC) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional 5.7 liter gasoline engine, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The ETC indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Electronic Throttle Control in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ETC indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Electronic Throttle Control Indicator > Component Information > Description and Operation > Description > Page 16184 Electronic Throttle Control Indicator: Description and Operation Operation OPERATION The Electronic Throttle Control (ETC) indicator gives an indication to the vehicle operator when the ETC system, or a circuit or component of the system is ineffective. The ETC indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The ETC indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the ETC indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the ETC indicator is illuminated for about six seconds. The entire bulb test is a function of the PCM. - ETC Indicator Lamp-On Message - Each time the cluster receives an electronic ETC indicator lamp-ON message from the PCM, the ETC indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the PCM message. The indicator remains illuminated solid or continues to flash for about 12 seconds or until the cluster receives a lamp-OFF message from the PCM, whichever is longer. If the indicator is illuminated solid with the engine running the vehicle will usually remain drivable. If the indicator is flashing with the engine running the vehicle may require towing. A flashing indicator means the ETC system requires immediate service. The indicator will be extinguished when the ignition switch is turned to the OFF position. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the PCM for three consecutive seconds, the ETC indicator is illuminated. The indicator remains illuminated until the cluster receives a single lamp-OFF message from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the ETC indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The actuator test illumination of the ETC indicator is a function of the PCM. The PCM continually monitors the ETC system circuits and sensors to decide whether the system is in good operating condition. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the PCM sends a lamp-ON message after the bulb test, it indicates that the PCM has detected an ETC system malfunction or that the ETC system is ineffective. The PCM will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the ETC indicator fails to illuminate due to an open or short in the cluster ETC indicator circuit, the cluster sends a message notifying the PCM of the condition, then the EMIC and the PCM will each store a DTC. For proper diagnosis of the ETC system, the PCM, the EMIC, the CAN data bus or the electronic communication related to ETC indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Exhaust Brake Switch > Component Information > Locations Exhaust Brake Switch: Locations Component ID: 465 Component : SWITCH-EXHAUST BRAKE Connector: Name : SWITCH-EXHAUST BRAKE Color : # of pins : 6 Qualifier : (6.7L) Pin Description Circuit 1 GROUND Z933 20BK/BR 2 PANEL LAMPS DRIVER E11 20OR/DB 3 EXHAUST BRAKE SWITCH SIGNAL G905 20BR/OR 4 S/C SWITCH RETURN V937 20VT/BR 5 EXHAUST BRAKE LAMP SIGNAL G904 20VT/DG 6-- Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Exhaust Brake Switch > Component Information > Locations > Page 16188 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Exhaust Brake Switch > Component Information > Locations > Page 16189 Exhaust Brake Switch: Diagrams Component ID: 465 Component : SWITCH-EXHAUST BRAKE Connector: Name : SWITCH-EXHAUST BRAKE Color : # of pins : 6 Qualifier : (6.7L) Pin Description Circuit 1 GROUND Z933 20BK/BR 2 PANEL LAMPS DRIVER E11 20OR/DB 3 EXHAUST BRAKE SWITCH SIGNAL G905 20BR/OR 4 S/C SWITCH RETURN V937 20VT/BR 5 EXHAUST BRAKE LAMP SIGNAL G904 20VT/DG 6-- Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Exhaust Brake Switch > Component Information > Locations > Page 16190 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fog/Driving Lamp Indicator > Component Information > Description and Operation > Description Fog/Driving Lamp Indicator: Description and Operation Description DESCRIPTION A fog lamp indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with optional fog lamps, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The fog lamp indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Front Fog Light in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A green Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in green through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The fog lamp indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fog/Driving Lamp Indicator > Component Information > Description and Operation > Description > Page 16195 Fog/Driving Lamp Indicator: Description and Operation Operation OPERATION The fog lamp indicator gives an indication to the vehicle operator whenever the optional fog lamps are illuminated. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The fog lamp indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will allow this indicator to operate whenever the instrument cluster receives a battery current input on the fused B(+) circuit. Therefore, the LED can be illuminated regardless of the ignition switch position. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the fog lamp indicator for the following reasons: - Fog Indicator Lamp-On Message - Each time the cluster receives an electronic fog indicator lamp-ON message from the TIPM indicating the fog lamp circuit is energized, the fog lamp indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the exterior lamp load shedding (battery saver) timed interval expires, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the fog lamp indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors electronic exterior lighting switch status messages from the ElectroMechanical Instrument Cluster (EMIC) to determine the appropriate outputs to the fog lamps. The TIPM activates or deactivates the fog lamp circuit then sends the proper lamp-ON or lamp-OFF message back to the EMIC. For proper diagnosis of the fog lamp system, the TIPM, the EMIC, the CAN data bus or the electronic communication related to fog lamp indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description Four Wheel Drive Indicator Lamp: Description and Operation Description 4WD Auto Indicator 4WD AUTO INDICATOR A 4WD auto indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD auto indicator is located on the right side of the instrument cluster, to the right of the oil pressure gauge. The 4WD auto indicator consists of a stencil-like cutout of the text 4WD AUTO in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD auto indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD auto indicator is serviced as a unit with the instrument cluster. 4WD Indicator 4WD INDICATOR Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 16200 A 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional four-wheel drive system, this indicator is electronically disabled. The 4WD indicator is located on the right side of the instrument cluster, to the right of the oil pressure gauge. The 4WD indicator consists of a stencil-like cutout of the text 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD indicator is serviced as a unit with the instrument cluster. 4WD Low Indicator 4WD LOW INDICATOR A 4WD low indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD low indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The 4WD low indicator consists of a stencil-like cutout of the text 4WD LOW in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD low indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD low indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 16201 Four Wheel Drive Indicator Lamp: Description and Operation Operation 4WD Auto Indicator 4WD AUTO INDICATOR The 4WD auto indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD auto mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD auto indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD auto indicator for the following reasons: - 4WD Auto Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD auto indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD auto indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD auto mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD auto indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD auto indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. 4WD Indicator 4WD INDICATOR The 4WD indicator gives an indication to the vehicle operator when the transfer case has been shifted into a 4WD mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD indicator for the following reasons: - 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly or the manual transfer case through the transfer case switch to determine when the 4WD mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the transfer case switch, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. 4WD Low Indicator 4WD LOW INDICATOR The 4WD low indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD low mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD low indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 16202 indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD low indicator for the following reasons: - 4WD Low Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD low indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD low indicator will be turned ON, then OFF again during the LED portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD low mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the 4WD low indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transfer case shift motor/mode sensor, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD low indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 16207 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 16208 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 16209 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 16210 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 16211 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 16212 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 16213 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 16214 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 16215 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 16216 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 16217 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 16218 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 16219 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 16220 Fuel Gauge: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 16221 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 16222 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 16223 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 16224 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation > Description Fuel Gauge: Description and Operation Description DESCRIPTION A fuel gauge is standard equipment on all instrument clusters. This gauge is located in the lower left quadrant of the instrument cluster, below the voltage gauge. This gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from E (or Empty) to F (or Full). An International Control and Display Symbol icon for Fuel is located on the cluster overlay, directly below the right end of the gauge scale. An arrowhead pointed to the left side of the vehicle is imprinted on the cluster overlay next to the Fuel icon on the gauge to provide the driver with a reminder as to the location of the fuel filler access. On vehicles equipped with a diesel engine, text that specifies DIESEL ONLY is located across the fuel gauge below the gauge scale, but above the hub of the gauge needle. The fuel gauge graphics are black against a white field except for a single red graduation at the low end of the gauge scale making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster general illumination lighting with the exterior lamps turned ON, the black gauge graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The fuel gauge is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation > Description > Page 16227 Fuel Gauge: Description and Operation Operation OPERATION The fuel gauge gives an indication to the vehicle operator of the level of fuel in the fuel tank. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and a hard wired input received by the cluster from the fuel level sending unit on the fuel pump module in the fuel tank. The fuel gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Fuel Level Sending Unit Input - The cluster provides a constant current source to the fuel level sending unit and monitors a return input on a fuel level sense circuit. The resistance through the fuel level sending unit increases as the fuel level falls and decreases as the fuel level rises causing changes in the fuel level sense input voltage. The cluster programming applies an algorithm to calculate the proper fuel gauge needle position based upon the fuel level sense input, then moves the gauge needle to the proper relative position on the gauge scale. This algorithm is used to dampen gauge needle movement against the negative effect that fuel sloshing within the fuel tank can have on accurate inputs from the fuel tank sending unit to the cluster. - Less Than 15 Percent Tank Full Input - Each time the fuel level sense input to the cluster indicates the fuel tank is about 15 percent full or less for 10 consecutive seconds and the vehicle speed is zero, or for 60 consecutive seconds and the vehicle speed is greater than zero, the gauge needle is moved to about the one-sixteenth graduation on the gauge scale, the low fuel indicator is illuminated, and a single chime tone is sounded. The low fuel indicator remains illuminated until the fuel level sense input is greater than about 15 percent full for 10 consecutive seconds and the vehicle speed is zero, or for 60 consecutive seconds and the vehicle speed is greater than zero, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the low fuel indicator is cycled OFF and then ON again by the appropriate inputs from the fuel level sending unit. - Less Than Empty Stop Input - Each time the cluster receives a fuel level sense input that indicates the fuel level in the fuel tank is less than the EMPTY gauge needle stop position, the gauge needle is moved to the low end of the gauge scale and the low fuel indicator is illuminated immediately. This input would indicate that the fuel level sense input to the cluster is a short circuit. - More Than Full Stop Input - Each time the cluster receives a fuel level sense input that indicates the fuel level in the fuel tank is more than the FULL gauge needle stop position, the gauge needle is moved to the low end of the gauge scale and the low fuel indicator is illuminated immediately. This input would indicate that the fuel level sense input to the cluster is an open circuit. - Actuator Test - Each time the cluster is put through the actuator test, the fuel gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The ElectroMechanical Instrument Cluster (EMIC) continually monitors the fuel tank sending unit to determine the level of fuel in the fuel tank. The EMIC then sends the proper electronic fuel level message to other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. For proper diagnosis of the fuel tank sending unit, the EMIC, the CAN data bus or the electronic communication related to fuel gauge operation or fuel level data processing a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16232 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16233 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16234 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16235 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16236 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16237 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16238 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16239 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16240 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16241 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16242 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16243 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16244 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16245 Fuel Gauge Sender: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16246 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16247 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16248 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16249 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Page 16250 Fuel Gauge Sender: Description and Operation DESCRIPTION The fuel tank module is installed in the top of the fuel tank. The fuel tank module contains the following components: - An electric fuel transfer (lift) pump - Fuel reservoir - A separate in-tank fuel filter - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection - A special lockring to retain module to fuel tank - Fuel return line connection. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Removal Fuel Gauge Sender: Service and Repair Removal REMOVAL 1. Drain and remove fuel tank. 2. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose. 3. Position Special Tool 9340 (3) into notches on outside edge of lockring (5). 4. Install 1/2 inch drive breaker bar (1) to tool 9340 (3). 5. Rotate breaker bar counterclockwise to remove lockring. 6. Remove lockring. The module will spring up slightly when lockring is removed. 7. Remove module from fuel tank. Be careful not to bend float arm while removing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Removal > Page 16253 Fuel Gauge Sender: Service and Repair Installation INSTALLATION CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced. 1. Using a new seal (gasket), position fuel pump module into opening in fuel tank. 2. Position lockring (5) over top of fuel pump module. 3. Rotate module until embossed alignment arrow points to center alignment mark. This step must be performed to prevent float from contacting side of fuel tank. Also be sure fuel fitting on top of pump module is pointed to drivers side of vehicle. 4. Install Special Tool 9340 (3) to lockring. 5. Install 1/2 inch drive breaker (1) into Special Tool 9340 (3). 6. Tighten lockring (clockwise) until all seven notches have engaged. 7. Install fuel tank. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > High Idle Switch > Component Information > Locations High Idle Switch: Locations Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > High Idle Switch > Component Information > Locations > Page 16257 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > High Idle Switch > Component Information > Locations > Page 16258 High Idle Switch: Diagrams Component ID: 210 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Description Circuit 1 5 VOLT SUPPLY K854 18VT/BR 2 APPS NO. 2 RETURN K400 18BR/VT 3 REMOTE THROTTLE SIGNAL K128 18DB/LG 4 REMOTE THROTTLE SWITCH SIGNAL K129 18DB/DG 5 MAXIMUM OPERATING SPEED SWITCH SIGNAL K119 18LG/BK 6 ACCELERATOR INTERLOCK SWITCH SIGNAL K810 18VT/DG 7 REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL F425 18PK 8 S/C SWITCH RETURN V937 18VT/BR 9 IN CAB POWER TAKEOFF SWITCH INPUT K425 18OR/BR 10 - Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > High Idle Switch > Component Information > Locations > Page 16259 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation Air Bag(s) Arming and Disarming: Technical Service Bulletins Air Bag System - Passenger Air Bag Deactivation NUMBER: 08-001-07 REV. B GROUP: Electrical DATE: May 16, 2007 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED. THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION. DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION. SUBJECT: Passenger Air Bag Deactivation MODELS: 2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 0300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakoka 2006 - 2007 (DR) Ram Truck 2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 16265 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet. NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States. PARTS REQUIRED: POLICY: Information Only Disclaimer: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 16266 This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair > Removal Instrument Panel Bulb: Service and Repair Removal Bulb - EVIC Control BULB - EVIC CONTROL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: There are provisions for up to four bulb/bulb holder units on the Electronic Vehicle Information Center (EVIC) circuit board. The two outboard bulbs illuminate the EVIC push buttons, while the two center bulbs illuminate the optional universal transmitter push buttons. Therefore, the center bulb locations are only populated on vehicles equipped with the optional universal transmitter. 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console (1) from the headliner. 3. Use a small thin-bladed screwdriver to rotate the bulb holder (3) counterclockwise about 30 degrees to unlock it from the keyed opening in the Electronic Vehicle Information Center (EVIC) unit (2) circuit board. 4. Pull the bulb holder and bulb straight out of the circuit board. Bulb - A/C-Heat Control BULB - A/C-HEAT CONTROL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: There may be minor variations in the locations of the bulb/bulb holder units on the back of the single zone A/C-heater controls as a result of various optional control units. However, the bulb types and service procedures are identical for each of these bulbs. The illumination provisions for the dual zone A/C-heater controls are NOT serviceable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair > Removal > Page 16271 1. Disconnect and isolate the battery negative cable. 2. Remove the center bezel from the instrument panel. 3. Use a small thin-bladed screwdriver to rotate the bulb holder (2) counterclockwise about 30 degrees to unlock it from the keyed opening in the A/C-heater control (1) circuit board. 4. Pull the bulb holder and bulb straight out of the circuit board. Bulb - CMTC Control BULB - CMTC CONTROL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: There are provisions for up to three bulb/bulb holder units on the Compass Mini-Trip Computer (CMTC) circuit board. The two outboard bulbs illuminate the CMTC push buttons, while the center bulb illuminates the optional universal transmitter push buttons. Therefore, the center bulb location is only populated on vehicles equipped with the optional universal transmitter. 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console (1) from the headliner. 3. Use a small thin-bladed screwdriver to rotate the bulb holder (3) counterclockwise about 30 degrees to unlock it from the keyed opening in the Compass Mini-Trip Computer (CMTC) unit (2) circuit board. 4. Pull the bulb holder and bulb straight out of the circuit board. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair > Removal > Page 16272 Instrument Panel Bulb: Service and Repair Installation Bulb - EVIC Control BULB - EVIC CONTROL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: There are provisions for up to four bulb/bulb holder units on the Electronic Vehicle Information Center (EVIC) circuit board. The two outboard bulbs illuminate the EVIC push buttons, while the two center bulbs illuminate the optional universal transmitter push buttons. Therefore, the center bulb locations are only populated on vehicles equipped with the optional universal transmitter. 1. Align the bulb holder and bulb (3) with the keyed opening in the circuit board of the Electronic Vehicle Information Center (EVIC) (2). 2. Insert the bulb holder and bulb straight into the circuit board until the bulb holder is firmly seated. 3. Using a small thin-bladed screwdriver, rotate the bulb holder clockwise about 30 degrees on the circuit board to lock it into place. 4. Reinstall the overhead console (1) onto the headliner. 5. Reconnect the battery negative cable. Bulb - A/C-Heat Control BULB - A/C-HEAT CONTROL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: There may be minor variations in the locations of the bulb/bulb holder units on the back of the single zone A/C-heater controls as a result of various optional control units. However, the bulb types and service procedures are identical for each of these bulbs. The illumination provisions for the dual zone A/C-heater controls are NOT serviceable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair > Removal > Page 16273 1. Align the bulb holder and bulb (2) with the keyed opening in the circuit board of the A/C-heater control (1). 2. Insert the bulb holder and bulb straight into the circuit board until the bulb holder is firmly seated. 3. Using a small thin-bladed screwdriver, rotate the bulb holder clockwise about 30 degrees on the circuit board to lock it into place. 4. Reinstall the center bezel onto the instrument panel. 5. Reconnect the battery negative cable. Bulb - CMTC Control BULB - CMTC CONTROL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: There are provisions for up to three bulb/bulb holder units on the Compass Mini-Trip Computer (CMTC) circuit board. The two outboard bulbs illuminate the CMTC push buttons, while the center bulb illuminates the optional universal transmitter push buttons. Therefore, the center bulb location is only populated on vehicles equipped with the optional universal transmitter. 1. Align the bulb holder and bulb (3) with the keyed opening in the circuit board of the Compass Mini-Trip Computer (CMTC) (2). 2. Insert the bulb holder and bulb straight into the circuit board until the bulb holder is firmly seated. 3. Using a small thin-bladed screwdriver, rotate the bulb holder clockwise about 30 degrees on the circuit board to lock it into place. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair > Removal > Page 16274 4. Reinstall the overhead console (1) onto the headliner. 5. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation > Description Low Fuel Lamp/Indicator: Description and Operation Description DESCRIPTION A low fuel indicator is standard equipment on all instrument clusters. This indicator is located on the left side of the instrument cluster, to the left of the fuel gauge. The low fuel indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Fuel in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The low fuel indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation > Description > Page 16279 Low Fuel Lamp/Indicator: Description and Operation Operation OPERATION The low fuel indicator gives an indication to the vehicle operator when the level of fuel in the fuel tank becomes low. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and a hard wired input received by the cluster from the fuel level sending unit on the fuel pump module in the fuel tank. The low fuel indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the low fuel indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the low fuel indicator is illuminated for about two seconds as a bulb test. - Less Than 15 Percent Tank Full Input - The cluster provides a constant current source to the fuel level sending unit and monitors a return input on a fuel level sense circuit. The resistance through the fuel level sending unit increases as the fuel level falls and decreases as the fuel level rises causing changes in the sense input voltage. Each time the fuel level sense input to the cluster indicates the fuel tank is about 15 percent full or less for 10 consecutive seconds and the vehicle speed is zero, or for 60 consecutive seconds and the vehicle speed is greater than zero, the fuel gauge needle is moved to about the one-sixteenth graduation on the gauge scale, the low fuel indicator is illuminated, and a single chime tone is sounded. The low fuel indicator remains illuminated until the fuel level sense input indicates that the fuel tank is greater than about 15 percent full for 10 consecutive seconds and the vehicle speed is zero, or for 60 consecutive seconds and the vehicle speed is greater than zero, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the low fuel indicator is cycled OFF and then ON again by the appropriate inputs from the fuel level sending unit. - Less Than Empty Stop Input - Each time the cluster receives a fuel level sense input that indicates the fuel level in the fuel tank is less than the E (or Empty) gauge needle stop position, the gauge needle is moved to the low end of the gauge scale and the low fuel indicator is illuminated immediately. This input would indicate that the fuel level sense input to the cluster is a short circuit. - More Than Full Stop Input - Each time the cluster receives a fuel level sense input that indicates the fuel level in the fuel tank is more than the F (or Full) gauge needle stop position, the gauge needle is moved to the low end of the gauge scale and the low fuel indicator is illuminated immediately. This input would indicate that the fuel level sense input to the cluster is an open circuit. - Actuator Test - Each time the cluster is put through the actuator test, the low fuel indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The ElectroMechanical Instrument Cluster (EMIC) continually monitors the fuel tank sending unit to determine the level of fuel in the fuel tank. The EMIC then sends the proper electronic fuel level message to other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. For proper diagnosis of the fuel tank sending unit, the EMIC, the CAN data bus or the electronic communication related to low fuel indicator operation or fuel level data processing a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Description and Operation > Description Low Tire Pressure Indicator: Description and Operation Description DESCRIPTION A Tire Pressure Monitor (TPM) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional TPM, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The TPM indicator consists of a stencil-like cutout of an icon that represents a cross-section of a tire with a centered exclamation point in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The TPM indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Description and Operation > Description > Page 16284 Low Tire Pressure Indicator: Description and Operation Operation OPERATION The Tire Pressure Monitor (TPM) indicator gives an indication to the vehicle operator of the status of the TPM system. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Sentry Key REmote Entry Module (SKREEM) over the Controller Area Network (CAN) data bus. The TPM indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provide a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the TPM indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position, the SKREEM sends an electronic TPM indicator lamp-ON message to the cluster to illuminate the TPM indicator for about three seconds as a bulb test. - TPM Indicator Lamp-On Message - Each time the cluster receives an electronic TPM indicator lamp-ON message from the SKREEM, the TPM indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the SKREEM message. The indicator remains illuminated until the cluster receives a lamp-OFF message from the SKREEM or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no TPM lamp-ON or lamp-OFF messages from the SKREEM for six consecutive seconds, the TPM indicator is illuminated by the instrument cluster. The indicator remains controlled and illuminated by the cluster until a valid lamp-ON or lamp-OFF message is received from the SKREEM. - Actuator Test - Each time the cluster is put through the actuator test, the TPM indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The SKREEM performs a self-test each time the ignition switch is turned to the ON position to decide whether the TPM system is in good operating condition and whether the tire inflation pressures are too high or too low. The SKREEM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the instrument cluster turns ON the TPM indicator after the bulb test, it indicates that the inflation pressure of a tire is too low or that a malfunction has occurred and the TPM system is ineffective. For proper diagnosis of the TPM system, the SKREEM, the EMIC, the CAN data bus or the electronic communication related to TPM indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair > Procedures Maintenance Required Lamp/Indicator: Procedures DaimlerChrysler provides no information regarding a Maintenance Required Lamp/Indicator. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair > Procedures > Page 16289 Maintenance Required Lamp/Indicator: Reset Procedure PERFORM SERVICE INDICATOR - RESET The "Perform Service" message will display on the Electronic Vehicle Information Center each time you turn the ignition switch to the ON/RUN position to indicate a emission maintenance is required. To reset the "Perform Service" indicator system (after performing the scheduled maintenance) refer to the following procedure: - 1. Turn the ignition switch to the ON position (Do not start engine). - 2. Press and release the brake pedal two times. - 3. Fully depress the accelerator pedal slowly two times within 10 seconds. - 4. Turn the ignition switch to the OFF/LOCK position. NOTE: If the indicator message illumination when you start the vehicle, the "Perform Service" indicator did not reset. If necessary repeat this procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Description Malfunction Indicator Lamp: Description and Operation Description DESCRIPTION A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. This indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. The MIL consists of a stencil-like cutout of the International Control and Display Symbol icon for Engine in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The MIL is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Description > Page 16294 Malfunction Indicator Lamp: Description and Operation Operation OPERATION The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or the Engine Control Module (ECM) on vehicles with a diesel engine has recorded a Diagnostic Trouble Code (DTC) for an On-Board Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the PCM or ECM over the Controller Area Network (CAN) data bus. The MIL Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the MIL for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the indicator is illuminated for about two seconds as a bulb test. The entire bulb test is a function of the PCM or ECM. - MIL Lamp-On Message - Each time the cluster receives an electronic MIL lamp-ON message from the PCM or ECM, the indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the PCM or ECM message. For some DTCs, if a problem does not recur, the PCM or ECM will send a lamp-OFF message automatically. Other DTCs may require that a fault be repaired and the PCM or ECM be reset before a lamp-OFF message will be sent. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the PCM or ECM for about 10 seconds, the MIL is illuminated by the instrument cluster to indicate a loss of bus communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the PCM or ECM. - Actuator Test - Each time the cluster is put through the actuator test, the MIL indicator will be turned ON during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM or ECM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. The PCM or ECM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the EMIC turns ON the MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and emissions systems may require service. For proper diagnosis of the fuel and emissions systems, the PCM, the ECM, the EMIC, the CAN data bus or the electronic communication related to MIL operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Description Malfunction Indicator Lamp - Transfer Case: Description and Operation Description DESCRIPTION A service 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The service 4WD indicator consists of a stencil-like cutout of the text SVC 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The service 4WD indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Description > Page 16299 Malfunction Indicator Lamp - Transfer Case: Description and Operation Operation OPERATION The service 4WD indicator gives an indication to the vehicle operator when the Totally Integrated Power Module (TIPM) has recorded a Diagnostic Trouble Code (DTC) for an electronic transfer case circuit or component malfunction. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the TIPM over the Controller Area Network (CAN) data bus. The service 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the service 4WD indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the service 4WD indicator is illuminated for about two seconds as a bulb test. - Service 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic service 4WD indicator lamp-ON message from the TIPM, the service 4WD indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the TIPM for 10 seconds the service 4WD indicator is illuminated by the cluster to indicate a loss of TIPM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the TIPM. - Actuator Test - Each time the cluster is put through the actuator test, the service 4WD indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case control circuits and transfer case shift motor/mode sensor assembly to determine the condition of the system. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the service 4WD indicator or the instrument cluster circuitry that controls the LED, refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the TIPM, the EMIC, the CAN data bus or the electronic communication related to service 4WD indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation > Description Odometer: Description and Operation Description DESCRIPTION An odometer and trip odometer are standard factory-installed equipment in all instrument clusters. The odometer, trip odometer, and engine hours information are displayed in a common electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. This VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked lens located on the lower edge of the speedometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The odometer, trip odometer, and engine hours information are not displayed simultaneously. The trip odometer reset switch on the instrument cluster circuit board toggles the display between odometer and trip odometer modes by depressing the odometer/trip odometer switch button that extends through the lower edge of the cluster lens, just left of the tachometer. When the trip odometer information is displayed, the word TRIP is also illuminated in the lower right corner of the VFD in a blue-green color and at the same lighting level as the trip odometer information. The engine hours information replaces the selected odometer or trip odometer information whenever the ignition switch is in the ON position and the engine is not running. The odometer, trip odometer, and engine hours information is stored in the instrument cluster memory. This information can be increased when the proper inputs are provided to the instrument cluster, but the information cannot be decreased. The odometer can display values up to 999,999 kilometers (999,999 miles). The odometer latches at these values, and will not roll over to zero. The trip odometer can display values up to 999.9 kilometers (999.9 miles) before it rolls over to zero. Engine hours are displayed in the format, hr9999. The cluster will accumulate values up to 9,999 hours before the display rolls over to zero. The odometer display does not have a decimal point and will not show values less than a full unit (kilometer or mile), while the trip odometer display does have a decimal point and will show tenths of a unit (kilometer or mile). The unit of measure (kilometers or miles) for the odometer and trip odometer display is not shown in the VFD. The unit of measure for the instrument cluster odometer/trip odometer is selected at the time that it is manufactured, and cannot be changed. The odometer also has a RENTAL CAR mode, which will illuminate the odometer information in the VFD whenever the driver side front door is opened with the ignition switch in the OFF or ACCESSORY positions. During daylight hours (exterior lamps are OFF) the odometer VFD is illuminated at full brightness for clear visibility. At night (exterior lamps are ON), the VFD lighting level is adjusted with the other cluster general illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a PARADE mode position of the panel lamps dimmer thumbwheel allows the VFD to be illuminated at full brightness if the exterior lamps are turned ON during daylight hours. The odometer/trip odometer VFD, the trip odometer switch, and the trip odometer switch button are serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation > Description > Page 16304 Odometer: Description and Operation Operation OPERATION The odometer and trip odometer give an indication to the vehicle operator of the distance the vehicle has traveled. The engine hours give an indication of the cumulative engine-ON time. This indicator is controlled by the instrument cluster circuitry based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) or Engine Control Module (ECM) over the Controller Area Network (CAN) data bus. The odometer, trip odometer and engine hours information are displayed by the instrument cluster Vacuum Fluorescent Display (VFD). The VFD will display the odometer information whenever the driver side front door is opened with the ignition switch in the OFF or ACCESSORY positions, and will display the last previously selected odometer or trip odometer information when the ignition switch is turned to the ON or START positions. The instrument cluster circuitry controls the VFD and provides the following features: - Odometer/Trip Odometer Display Toggling - Actuating the trip odometer reset switch button momentarily with the VFD illuminated will toggle the display between the odometer and trip odometer information. Each time the VFD is illuminated with the ignition switch in the ON or START positions, the display will automatically return to the last mode previously selected (odometer or trip odometer). - Engine Hours Display Toggling - When the trip odometer reset switch button is pressed and held for longer than about six seconds with the ignition switch in the ON position and the engine speed message from the PCM is zero, the trip odometer information will be momentarily displayed, then the engine hours information will be displayed. The VFD must be displaying the odometer information when the trip odometer reset switch button is pressed in order to toggle to the engine hours display. The engine hours will remain displayed for about 30 seconds, until the engine speed message is greater than zero, or until the ignition switch is turned to the OFF position, whichever occurs first. - Trip Odometer Reset - When the trip odometer reset switch button is pressed and held for longer than about two seconds with the ignition switch in the ON or START position, the trip odometer will be reset to 0.0 kilometers (miles). The VFD must be displaying the trip odometer information in order for the trip odometer information to be reset. - GASCAP Message Display - On vehicles manufactured with a United States country code, each time the cluster receives an electronic message from the PCM indicating a monitored leak in the evaporative emissions system, the cluster replaces the displayed odometer/trip odometer value with the textual message, GASCAP. This message serves as a reminder to the vehicle operator to check that the gas cap is properly installed and tightened, but could also indicate another source of air leakage in the on-board evaporative and vapor recovery emissions systems. Unless the leak is corrected, this message will latch and remain displayed during the current and each subsequent ignition cycle until the trip odometer reset button is pressed and released momentarily, which will revert the display to the odometer/trip odometer information that was last displayed for the remainder of that ignition cycle. Once the source of a leak has been corrected, either momentarily pressing the trip odometer reset button or cycling the ignition switch will unlatch the message and return the odometer/trip odometer to normal operation. - Communication Error - If the cluster fails to receive an electronic distance message during normal operation, it will hold and display the last data received until the ignition switch is turned to the OFF position. If the cluster does not receive a distance message within one second after the ignition switch is turned to the ON position, it will display the last distance value stored in the cluster memory. If the cluster is unable to display distance information due to an error internal to the cluster, the VFD will display Error. - Actuator Test - Each time the cluster is put through the actuator test, the odometer VFD will display all of its segments simultaneously, then step through each character segment individually during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The PCM continually monitors the vehicle speed pulse information received from the Vehicle Speed Sensor (VSS) or the Controller Anti-lock Brake (CAB) and engine speed pulse information received from the crankshaft position sensor, then sends the proper messages to the ElectroMechanical Instrument Cluster (EMIC). For proper diagnosis of the VSS, the crankshaft position sensor, the CAB, the PCM, the EMIC, the CAN data bus or the electronic communication related to odometer/trip odometer operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair OIL CHANGE INDICATOR - RESET To reset the "Oil Change Required" indicator (after performing the scheduled maintenance) refer to the following procedure: 1. Turn the ignition switch to the ON position (Do not start engine). 2. Fully depress the accelerator pedal slowly three times within 10 seconds. 3. Turn the ignition switch to the OFF/LOCK position. NOTE: If the "Oil Change Required" indicator message illuminates when you start the vehicle, the indicator did not reset. If necessary repeat this procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Description and Operation > Description Oil Pressure Gauge: Description and Operation Description DESCRIPTION An oil pressure gauge is standard equipment on all instrument clusters. This gauge is located in the upper right quadrant of the instrument cluster, above the coolant temperature gauge. This gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from L (or Low) to H (or High) for gasoline engines. On vehicles with a diesel engine the scale reads from 0 kPa to 760 kPa in markets where a metric instrument cluster is specified, or from 0 psi to 110 psi in all other markets. An International Control and Display Symbol icon for Engine Oil is located on the cluster overlay, directly below the left end of the gauge scale. The oil pressure gauge graphics are black against a white field except for a single red graduation at the low end of the gauge scale making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster general illumination lighting with the exterior lamps turned ON, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The oil pressure gauge is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Description and Operation > Description > Page 16312 Oil Pressure Gauge: Description and Operation Operation OPERATION The oil pressure gauge gives an indication to the vehicle operator of the engine oil pressure. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Controller Area Network (CAN) data bus. The oil pressure gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Oil Pressure Message - The instrument cluster circuitry restricts the oil pressure gauge needle operation in order to provide readings that are consistent with customer expectations. Each time the cluster receives an electronic engine oil pressure message from the PCM or ECM indicating the pressure is above about 41 kPa (6 psi) the cluster holds the gauge needle at a point near the middle increment within the normal range on the gauge scale. - Engine Oil Pressure Low Message - Each time the cluster receives three consecutive electronic engine oil pressure messages from the PCM or ECM indicating the pressure is below about 41 kPa (6 psi), the gauge needle is moved to the red graduation at the far left end of the gauge scale, the check gauges indicator is illuminated, and a single chime tone is generated. The gauge needle remains at the left end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the pressure is above about 41 kPa (6 psi), or until the ignition switch is turned to the OFF position, whichever occurs first. The cluster will only turn ON the check gauges indicator in response to a low pressure message if the engine speed is greater than zero. - Communication Error - If the cluster fails to receive an engine oil pressure message, it will hold the gauge needle at the last indication for about 10 seconds, or until the ignition switch is turned to the OFF position, whichever occurs first. After 10 seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the oil pressure gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM (gasoline engines) or ECM (diesel engines) continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM or ECM then sends the proper messages to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the oil pressure gauge or the instrument cluster circuitry that controls the gauge refer to Instrument Cluster/Carrier Testing. If the instrument cluster turns ON the check gauges indicator due to a low oil pressure gauge reading, it may indicate that the engine or the engine oiling system requires service. For proper diagnosis of the engine oil pressure sensor, the PCM, the ECM, the EMIC, the CAN data bus or the electronic communication related to oil pressure gauge operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Component ID: 473 Component : SWITCH-OIL PRESSURE Connector: Name : SWITCH-OIL PRESSURE Color : BLACK # of pins : 2 Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 18VT/GY Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 16VT/GY 2-Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 16316 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 16317 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 16318 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 16319 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 16320 Oil Pressure Sender: Diagrams Component ID: 473 Component : SWITCH-OIL PRESSURE Connector: Name : SWITCH-OIL PRESSURE Color : BLACK # of pins : 2 Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 18VT/GY Pin Description Circuit 1 OIL PRESSURE SIGNAL G6 16VT/GY 2-Component Location - 8 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 16321 Component Location - 11 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 16322 Component Location - 12 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 16323 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 16324 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Service and Repair > Removal Oil Pressure Sender: Service and Repair Removal REMOVAL NOTE: When installing a new oil pressure switch, the kit will include a special 90° fitting that must be installed. Clock the fitting and switch assembly between the 1:00 o'clock and 2:00 o'clock position. Torque the fitting bolt to 18 Nm (13 ft. lbs) 1. Disconnect the battery negative cables. 2. Disconnect the oil pressure switch connector. 3. Using a suitable socket, remove the oil pressure switch from the block (counter-clockwise). 4. Remove the banjo screw from the oil pressure switch mounting block. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Service and Repair > Removal > Page 16327 Oil Pressure Sender: Service and Repair Installation INSTALLATION 1. Install banjo screw through the oil pressure switch mounting block. The switch mounting block port (oil switch port) should point to the 2 o'clock position. Torque the banjo screw to 24 Nm or 18 ft lbs. 2. If the switch is not being replaced, replace and lubricate the o-ring. 3. Install the oil pressure switch and tighten to 18 Nm (159 in. lbs.) torque. 4. Connect oil pressure switch connector. 5. Connect the battery negative cables. 6. Start engine and check for oil leaks at the switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator Overdrive Indicator Lamp: Description and Operation Overdrive Off Indicator Description DESCRIPTION An overdrive off indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The overdrive off indicator consists of a stencil-like cutout of the text O/D OFF in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the overdrive off indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The overdrive off indicator is serviced as a unit with the instrument cluster. Operation OPERATION The overdrive off indicator gives an indication to the vehicle operator when the overdrive-OFF position of the tow/haul switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The overdrive off indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the overdrive off indicator for the following reasons: - Overdrive Off Indicator Lamp-On Message - Each time the cluster receives an electronic overdrive off indicator lamp-ON message from the PCM indicating that the overdrive-OFF position of the tow/haul switch has been selected, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the overdrive off indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the overdrive off indicator or the instrument cluster circuitry that controls the indicator, refer to Instrument Cluster/Carrier Testing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 16332 For proper diagnosis of the transmission control system, the PCM, the EMIC, the CAN data bus or the electronic communication related to overdrive off indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 16333 Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator Description DESCRIPTION A tow/haul indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The tow/haul indicator consists of a stencil-like cutout of the text TOW/HAUL in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the tow/haul indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The tow/haul indicator is serviced as a unit with the instrument cluster. Operation OPERATION The tow/haul indicator gives an indication to the vehicle operator when the tow/haul function of the tow/haul switch has been selected, revising the shift schedule of the electronically controlled automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The tow/haul indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the tow/haul indicator for the following reasons: - Tow/Haul Indicator Lamp-On Message - Each time the cluster receives an electronic tow/haul indicator lamp-ON message from the PCM indicating that the tow/haul shift schedule has been selected, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the tow/haul indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the tow/haul indicator or the instrument cluster circuitry that controls the indicator refer to Instrument Cluster / Carrier testing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 16334 For proper diagnosis of the transmission control system, the PCM, the EMIC, the CAN data bus or the electronic communication related to tow/haul indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Component ID: 474 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : GRAY # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 16338 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 16339 Parking Brake Warning Switch: Diagrams Component ID: 474 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : GRAY # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 16340 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Description and Operation > Description Parking Brake Warning Switch: Description and Operation Description DESCRIPTION The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Description and Operation > Description > Page 16343 Parking Brake Warning Switch: Description and Operation Operation OPERATION The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Description and Operation > Page 16344 Parking Brake Warning Switch: Testing and Inspection PARK BRAKE SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: If the brake indicator stays ON with the ignition switch in the ON position and the park brake released, or comes ON while driving, the brake system must be diagnosed and repaired prior to performing the following tests. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an ineffective park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to STEP 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OKAY 3. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to STEP 2. If not OK, replace the ineffective park brake switch. 4. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Service and Repair > Removal Parking Brake Warning Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Service and Repair > Removal > Page 16347 Parking Brake Warning Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Reach under the left end of the instrument panel to position the park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 Nm (24 in. lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. 5. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation > Description Seat Belt Reminder Lamp: Description and Operation Description DESCRIPTION A seatbelt indicator is standard equipment on all instrument clusters. The seatbelt indicator is located near the upper edge of the instrument cluster, between the tachometer and the speedometer. The seatbelt indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Seat Belt in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The seatbelt indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation > Description > Page 16352 Seat Belt Reminder Lamp: Description and Operation Operation OPERATION The seatbelt indicator gives an indication to the vehicle operator of the status of the driver side front seatbelt. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and a hard wired input from the seatbelt switch in the driver side front seatbelt buckle through the seat belt indicator driver circuit. The seatbelt indicator also includes a programmable enhanced seatbelt reminder or BELTMINDER feature that is enabled when the vehicle is shipped from the factory. This BELTMINDER feature can be disabled and enabled by the customer using a specific programming event sequence, or by the dealer using a diagnostic scan tool. The seatbelt indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the seatbelt indicator for the following reasons: - Seatbelt Reminder Function - Each time the cluster receives a battery current input on the fused ignition switch output (run-start) circuit, the indicator will be illuminated as a seatbelt reminder for about six seconds, or until the ignition switch is turned to the OFF position, whichever occurs first. This reminder function will occur regardless of the status of the seatbelt switch input to the cluster. - Driver Side Front Seatbelt Not Buckled - Beltminder Active - Following the seatbelt reminder function, each time the cluster detects an open circuit on the seat belt indicator driver circuit (seatbelt switch open = seatbelt unbuckled) with the ignition switch in the START or ON positions, the indicator will be illuminated. In addition, if the driver side front seat belt remains unbuckled about 60 seconds after the conclusion of the seatbelt reminder function with the vehicle speed greater than about 8 kilometers-per-hour (5 miles-per-hour), the seatbelt indicator will begin to cycle between flashing ON and OFF for 3 seconds, then lighting solid for 2 seconds. The seatbelt indicator will continue to cycle between flashing and solid illumination for 13 complete cycles, until the seat belt indicator driver input to the cluster is closed to ground (seatbelt switch closed = seatbelt buckled), or until the ignition switch is turned to the OFF position, whichever occurs first. - Driver Side Front Seatbelt Not Buckled - Beltminder Inactive - Following the seatbelt reminder function, each time the cluster detects an open circuit on the seat belt indicator driver circuit (seatbelt switch open = seatbelt unbuckled) with the ignition switch in the START or ON positions, the indicator will be illuminated. The seatbelt indicator remains illuminated until the seat belt indicator driver input to the cluster is closed to ground (seatbelt switch closed = seatbelt buckled), or until the ignition switch is turned to the OFF position, whichever occurs first. - Airbag Indicator Backup - If the instrument cluster detects a fault in the airbag indicator circuit it will send an electronic message indicating the fault to the Occupant Restraint Controller (ORC), then flash the seatbelt indicator ON and OFF. The cluster will continue to flash the indicator until the airbag indicator circuit fault is resolved, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the seatbelt indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The seatbelt switch is connected in series between ground and the seat belt indicator driver input to the instrument cluster. The hard wired seatbelt switch input to the instrument cluster may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Description and Operation > Description Door Switch: Description and Operation Description DESCRIPTION This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if ineffective or damaged, the door latch unit must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Description and Operation > Description > Page 16358 Door Switch: Description and Operation Operation OPERATION The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper electronic door ajar switch status messages to other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. The door ajar switches as well as the hard wired inputs and outputs of the switches may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16363 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16364 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16365 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16366 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16367 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16368 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16369 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16370 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16371 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16372 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16373 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16374 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16375 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16376 Fuel Gauge Sender: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16377 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16378 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16379 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 16380 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 16381 Fuel Gauge Sender: Description and Operation DESCRIPTION The fuel tank module is installed in the top of the fuel tank. The fuel tank module contains the following components: - An electric fuel transfer (lift) pump - Fuel reservoir - A separate in-tank fuel filter - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection - A special lockring to retain module to fuel tank - Fuel return line connection. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Removal Fuel Gauge Sender: Service and Repair Removal REMOVAL 1. Drain and remove fuel tank. 2. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose. 3. Position Special Tool 9340 (3) into notches on outside edge of lockring (5). 4. Install 1/2 inch drive breaker bar (1) to tool 9340 (3). 5. Rotate breaker bar counterclockwise to remove lockring. 6. Remove lockring. The module will spring up slightly when lockring is removed. 7. Remove module from fuel tank. Be careful not to bend float arm while removing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Removal > Page 16384 Fuel Gauge Sender: Service and Repair Installation INSTALLATION CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced. 1. Using a new seal (gasket), position fuel pump module into opening in fuel tank. 2. Position lockring (5) over top of fuel pump module. 3. Rotate module until embossed alignment arrow points to center alignment mark. This step must be performed to prevent float from contacting side of fuel tank. Also be sure fuel fitting on top of pump module is pointed to drivers side of vehicle. 4. Install Special Tool 9340 (3) to lockring. 5. Install 1/2 inch drive breaker (1) into Special Tool 9340 (3). 6. Tighten lockring (clockwise) until all seven notches have engaged. 7. Install fuel tank. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Component ID: 474 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : GRAY # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 16388 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 16389 Parking Brake Warning Switch: Diagrams Component ID: 474 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : GRAY # of pins : 1 Pin Description Circuit 1 PARK BRAKE SWITCH SENSE B25 20DG/WT Component Location - 31 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 16390 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Description Parking Brake Warning Switch: Description and Operation Description DESCRIPTION The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Description > Page 16393 Parking Brake Warning Switch: Description and Operation Operation OPERATION The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Page 16394 Parking Brake Warning Switch: Testing and Inspection PARK BRAKE SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: If the brake indicator stays ON with the ignition switch in the ON position and the park brake released, or comes ON while driving, the brake system must be diagnosed and repaired prior to performing the following tests. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an ineffective park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to STEP 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OKAY 3. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to STEP 2. If not OK, replace the ineffective park brake switch. 4. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Removal Parking Brake Warning Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Removal > Page 16397 Parking Brake Warning Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Reach under the left end of the instrument panel to position the park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 Nm (24 in. lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. 5. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Sensor-Water In Fuel Water In Fuel Sensor: Locations Sensor-Water In Fuel Component ID: 433 Component : SENSOR-WATER IN FUEL Connector: Name : SENSOR-WATER IN FUEL Color : BLACK # of pins : 2 Qualifier : (5.9L) A WATER IN FUEL SENSOR GROUND K923 18BR/WT B WATER IN FUEL SENSOR SIGNAL G123 18VT/LG Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Sensor-Water In Fuel > Page 16402 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Sensor-Water In Fuel > Page 16403 Connector: Name : SENSOR-WATER IN FUEL Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Sensor-Water In Fuel > Page 16404 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Sensor-Water In Fuel > Page 16405 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Sensor-Water In Fuel > Page 16406 Water In Fuel Sensor: Locations Water - In - Fuel Sensor The WIF sensor (2) is located on the bottom of the fuel filter housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 16407 Water In Fuel Sensor: Diagrams Component ID: 433 Component : SENSOR-WATER IN FUEL Connector: Name : SENSOR-WATER IN FUEL Color : BLACK # of pins : 2 Qualifier : (5.9L) A WATER IN FUEL SENSOR GROUND K923 18BR/WT B WATER IN FUEL SENSOR SIGNAL G123 18VT/LG Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 16408 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 16409 Connector: Name : SENSOR-WATER IN FUEL Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 16410 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 16411 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Description and Operation > Description Water In Fuel Sensor: Description and Operation Description DESCRIPTION The Water-In-Fuel (WIF) sensor (2) is located on the bottom of the fuel filter/water separator canister (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Description and Operation > Description > Page 16414 Water In Fuel Sensor: Description and Operation Operation OPERATION The sensor sends an input to the Engine Control Module (ECM) when it senses water in the fuel filter/water separator. As the water level in the filter/separator increases, the resistance across the WIF sensor decreases. This decrease in resistance is sent as a signal to the ECM and compared to a high water standard value. Once the value reaches 30 to 40 kilohms, the ECM will activate the water-in-fuel warning lamp through CCD bus circuits. This all takes place when the ignition key is initially put in the ON position. The ECM continues to monitor the input while the engine is running. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Description and Operation > Page 16415 Water In Fuel Sensor: Service and Repair Water-In-Fuel (WIF) Sensor Replacement: The WIF sensor (2) is located on the bottom of the fuel filter housing. The WIF sensor is not a separately serviceable item. If diagnostics have led you to replace this sensor, then the whole fuel filter assembly (1) needs to be changed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation > Description Speedometer Head: Description and Operation Description DESCRIPTION A speedometer is standard equipment on all instrument clusters. The speedometer is located next to the tachometer, just to the right of center in the instrument cluster. The speedometer consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 210 degree primary scale on the gauge dial face. The speedometer reads left-to-right either from 0 to 120 mph, or from 0 to 200 km/h, depending upon the market for which the vehicle is manufactured. Each version also has a secondary inner scale on the gauge dial face that provides the equivalent opposite units from the primary scale. Text appearing on the cluster overlay just below the hub of the speedometer needle abbreviates the unit of measure for the primary scale (either MPH or km/h), followed by the unit of measure for the secondary scale. The speedometer graphics are black (primary scale) and blue (secondary scale) against a white field making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster general illumination lighting with the exterior lamps turned ON, the black graphics appear blue-green and the blue graphics appear light blue. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The speedometer is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation > Description > Page 16420 Speedometer Head: Description and Operation Operation OPERATION The speedometer gives an indication to the vehicle operator of the vehicle road speed. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The speedometer is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Vehicle Speed Message - Each time the cluster receives an electronicvehicle speed message from the PCM it will calculate the correct vehicle speed reading and position the gauge needle at that relative speed position on the gauge scale. The cluster will receive a new message and reposition the gauge pointer accordingly about every 88 milliseconds. The gauge needle will continually be positioned at the relative vehicle speed position on the gauge scale until the vehicle stops moving, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster fails to receive a speed message, it will hold the gauge needle at the last indication for about three seconds , or until the ignition switch is turned to the OFF position, whichever occurs first. After three seconds, the gauge needle will return to the left end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the speedometer needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM continually monitors the Vehicle Speed Sensor (VSS) or electronic wheel speed messages from the Controller Anti-lock Brake (CAB) to determine the vehicle road speed. The PCM then sends the proper vehicle speed messages to the ElectroMechanical Instrument Cluster (EMIC). For proper diagnosis of the VSS, the CAB, the PCM, the EMIC, the CAN data bus or the electronic communication related to speedometer operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Description and Operation > Description Tachometer: Description and Operation Description DESCRIPTION A tachometer is standard equipment on all instrument clusters. The tachometer is located to the left of the speedometer, just to the left of center in the instrument cluster. The tachometer consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 210 degree scale on the gauge dial face. The tachometer reads left-to-right from 0 to 7 for gasoline engines, or from 0 to 5 for diesel engines. The text RPM X 1000 is imprinted on the cluster overlay directly below the hub of the tachometer needle. This text identifies that each number on the tachometer scale is to be multiplied by 1000 rpm. The tachometer graphics are black against a white field making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster general illumination lighting with the exterior lamps turned ON, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by a replaceable incandescent bulb and holder unit located on the instrument cluster electronic circuit board. The tachometer is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Description and Operation > Description > Page 16425 Tachometer: Description and Operation Operation OPERATION The tachometer gives an indication to the vehicle operator of the engine speed. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Controller Area Network (CAN) data bus. The tachometer is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Speed Message - Each time the cluster receives an electronic engine speed message from the PCM or ECM it will calculate the correct engine speed reading and position the gauge needle at that relative speed position on the gauge scale. The cluster will receive a new message and reposition the gauge pointer accordingly about every 88 milliseconds. The gauge needle will continually be repositioned at the relative engine speed position on the gauge scale until the engine stops running, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster fails to receive a speed message, it will hold the gauge needle at the last indication for about three seconds , or until the ignition switch is turned to the OFF position, whichever occurs first. After three seconds, the gauge needle will return to the left end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the tachometer needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the crankshaft position sensor to determine the engine speed. On vehicles with a diesel engine, the ECM continually monitors the engine speed sensor to determine the engine speed. The PCM or ECM then sends the proper engine speed messages to the ElectroMechanical Instrument Cluster (EMIC). For proper diagnosis of the crankshaft position sensor, the engine speed sensor, the PCM, the ECM, the EMIC, the CAN data bus or the electronic communication related to tachometer operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation > Description Temperature Gauge: Description and Operation Description DESCRIPTION An engine coolant temperature gauge is standard equipment on all instrument clusters. The engine coolant temperature gauge is located in the lower right quadrant of the instrument cluster, below the oil pressure gauge. The gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from C (or Cold) to H (or Hot) for gasoline engines. On vehicles with a diesel engine, the scale reads from 60° C to 120° C in markets where a metric instrument cluster is specified, or from 140° F to 245° F in all other markets. An International Control and Display Symbol icon for Engine Coolant Temperature is located on the cluster overlay, directly below the left end of the gauge scale. The engine coolant temperature gauge graphics are black against a white field except for a single red graduation at the high end of the gauge scale making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the black gauge graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The engine coolant temperature gauge is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation > Description > Page 16430 Temperature Gauge: Description and Operation Operation OPERATION The engine coolant temperature gauge gives an indication to the vehicle operator of the engine coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Controller Area Network (CAN) data bus. The engine coolant temperature gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Temperature Message - Each time the cluster receives an electronic engine temperature message from the PCM or ECM indicating the temperature is between the low end of normal about 54° C (130° F) for gasoline engines, or about 60° C (140° F) for diesel engines] and the high end of normal about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines], the gauge needle is moved to the actual relative temperature position on the gauge scale. - Engine Temperature Low Message - Each time the cluster receives an electronic engine temperature message from the PCM or ECM indicating the temperature is below the low end of normal about 54° C (130° F) for gasoline engines, or about 60° C (140° F) for diesel engines], the gauge needle is held at the graduation on the far left end of the gauge scale. The gauge needle remains at the low end of the gauge scale until the cluster receives a message from the PCM or ECM indicating the temperature is above about 54° C (130° F) for gasoline engines, or about 60° C (140° F) for diesel engines, or until the ignition switch is turned to the OFF position, whichever occurs first. - Engine Temperature High Message - Each time the cluster receives three consecutive electronic engine temperature messages from the PCM or ECM indicating the temperature is above about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, the gauge needle is moved to the red increment or zone at the far right end of gauge scale, the check gauges indicator is illuminated, and a single chime tone is sounded. The gauge needle remains at the high end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the temperature is below about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the check gauges indicator is cycled OFF and then ON again by the appropriate messages from the PCM or ECM. - Communication Error - If the cluster fails to receive an engine temperature message, it will hold the gauge needle at the last indication for about 10 seconds or until the ignition switch is turned to the OFF position, whichever occurs first. After 10 seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the engine coolant temperature gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM (gasoline engine) or ECM (diesel engine) continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM or ECM then sends the proper messages to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the engine coolant temperature gauge or the instrument cluster circuitry that controls the gauge refer to Instrument Cluster/Carrier Testing. If the instrument cluster turns ON the check gauges indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. For proper diagnosis of the engine coolant temperature sensor, the PCM, the ECM, the EMIC, the CAN data bus or the electronic communication related to engine coolant temperature gauge operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description Temperature Warning Indicator - A/T: Description and Operation Description DESCRIPTION A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The transmission over-temperature indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Transmission Temperature in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The transmission over-temperature indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description > Page 16435 Temperature Warning Indicator - A/T: Description and Operation Operation OPERATION The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received over the Controller Area Network (CAN) data bus from the Powertrain Control Module (PCM). The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Indicator Lamp-On Message - Each time the cluster receives an electronic trans over-temp indicator lamp-ON message from the PCM indicating that the transmission fluid temperature is 135° C (275° F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the indicator is cycled OFF and then ON again by the appropriate lamp-ON and lamp-OFF messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the transmission over-temperature indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the instrument cluster illuminates the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission or the transmission cooling system are being overloaded, or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED,refer to Instrument Cluster/Carrier Testing. For proper diagnosis of the transmission temperature sensor, the PCM, the EMIC, the CAN data bus or the electronic communication related to transmission over-temperature indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation > Description Low Tire Pressure Indicator: Description and Operation Description DESCRIPTION A Tire Pressure Monitor (TPM) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional TPM, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The TPM indicator consists of a stencil-like cutout of an icon that represents a cross-section of a tire with a centered exclamation point in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The TPM indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation > Description > Page 16441 Low Tire Pressure Indicator: Description and Operation Operation OPERATION The Tire Pressure Monitor (TPM) indicator gives an indication to the vehicle operator of the status of the TPM system. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Sentry Key REmote Entry Module (SKREEM) over the Controller Area Network (CAN) data bus. The TPM indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provide a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the TPM indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position, the SKREEM sends an electronic TPM indicator lamp-ON message to the cluster to illuminate the TPM indicator for about three seconds as a bulb test. - TPM Indicator Lamp-On Message - Each time the cluster receives an electronic TPM indicator lamp-ON message from the SKREEM, the TPM indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the SKREEM message. The indicator remains illuminated until the cluster receives a lamp-OFF message from the SKREEM or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no TPM lamp-ON or lamp-OFF messages from the SKREEM for six consecutive seconds, the TPM indicator is illuminated by the instrument cluster. The indicator remains controlled and illuminated by the cluster until a valid lamp-ON or lamp-OFF message is received from the SKREEM. - Actuator Test - Each time the cluster is put through the actuator test, the TPM indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The SKREEM performs a self-test each time the ignition switch is turned to the ON position to decide whether the TPM system is in good operating condition and whether the tire inflation pressures are too high or too low. The SKREEM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the instrument cluster turns ON the TPM indicator after the bulb test, it indicates that the inflation pressure of a tire is too low or that a malfunction has occurred and the TPM system is ineffective. For proper diagnosis of the TPM system, the SKREEM, the EMIC, the CAN data bus or the electronic communication related to TPM indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp > Component Information > Description and Operation > Electronic Stability Program/Brake Assist System Indicator Traction Control Indicator Lamp: Description and Operation Electronic Stability Program/Brake Assist System Indicator Description DESCRIPTION An Electronic Stability Program/Brake Assist System (ESP/BAS) indicator is only found in the instrument clusters for vehicles equipped with a gasoline engine. However, on vehicles not equipped with the optional ESP/BAS, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The ESP/BAS indicator consists of a stencil-like cutout of the text ESP BAS in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ESP/BAS indicator is serviced as a unit with the instrument cluster. Operation OPERATION The ESP/BAS indicator gives an indication to the vehicle operator when a problem has been detected in the Electronic Stability Program (ESP)/Brake Assist System (BAS). This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) and the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The ESP/BAS indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the ESP/BAS indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the ESP/BAS indicator is illuminated for about four seconds as a bulb test. - ESP/BAS Indicator Lamp-On Message - Each time the cluster receives an electronic ESP/BAS indicator lamp-ON message from the CAB or the TIPM, the ESP/BAS indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the CAB or TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the ESP/BAS indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The CAB and TIPM continually monitor the ESP/BAS system circuits and sensors to decide whether the system is in good operating condition and the proper outputs to the components of the system. The CAB or TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For proper diagnosis of the ESP/BAS system, the CAB, the TIPM, the EMIC, the CAN data bus or the electronic communication related to ESP/BAS Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp > Component Information > Description and Operation > Electronic Stability Program/Brake Assist System Indicator > Page 16446 indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp > Component Information > Description and Operation > Electronic Stability Program/Brake Assist System Indicator > Page 16447 Traction Control Indicator Lamp: Description and Operation Traction Control Indicator Description DESCRIPTION An Electronic Stability Program/Brake Assist System (ESP/BAS)/Traction Control System (TCS) traction control indicator is only found in the instrument clusters for vehicles equipped with a gasoline engine. However, on vehicles not equipped with the optional ESP/BAS/TCS, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The traction control indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Stability - Anti-Spin in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The traction control indicator is serviced as a unit with the instrument cluster. Operation OPERATION The traction control indicator gives an indication to the vehicle operator when the Electronic Stability Program (ESP)/Brake Assist System (BAS)/Traction Control System (TCS) has been activated. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Controller Area Network (CAN) data bus. The traction control indicator is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be OFF when the ignition switch is in any position except ON or START. The indicator only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the traction control indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the traction control indicator is illuminated for about four seconds as a bulb test. The entire bulb test is a function of the CAB. - Traction Control Indicator Lamp-On Message - Each time the cluster receives an electronic traction control indicator lamp-ON message from the CAB indicating that the ESP/BAS/TCS has been activated, the traction control indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the traction control indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The CAB continually monitors the status of the inputs to the ESP/BAS/TCS systems to determine the proper outputs to the components of the Antilock Brake System (ABS). The CAB then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the traction control indicator or the instrument cluster circuitry that controls the indicator, refer to Instrument Cluster/Carrier Testing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp > Component Information > Description and Operation > Electronic Stability Program/Brake Assist System Indicator > Page 16448 For proper diagnosis of the ESP/BAS/TCS, the CAB, the EMIC, the CAN data bus or the electronic communication related to traction control indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Description and Operation > Description Transmission Shift Position Indicator Lamp: Description and Operation Description DESCRIPTION An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this vehicle. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. This VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator displays the following characters from left to right: P, R, N, D, 2, and 1. Each character appears in a blue-green color and at the same lighting level as the odometer information. Respectively, these characters represent the PARK, REVERSE, NEUTRAL, DRIVE, second gear, and first gear positions of the transmission gear selector lever on the steering column. The indicator illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps are OFF) the gear selector indicator is illuminated at full brightness for clear visibility. At night (exterior lamps are ON), the indicator lighting level is adjusted with the other cluster general illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a PARADE mode position of the panel lamps dimmer thumbwheel allows the indicator to be illuminated at full brightness if the exterior lamps are turned ON during daylight hours. The gear selector indicator is serviced as a unit with the VFD unit in the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Description and Operation > Description > Page 16453 Transmission Shift Position Indicator Lamp: Description and Operation Operation OPERATION The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission type based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the OFF position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission type that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon an electronic selected gear message received from the Transmission Control Module (TCM) over the Controller Area Network (CAN) data bus. If the Transmission Range Sensor (TRS) mux circuit is open and no electronic selected gear messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the OFF position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the TRS. If the cluster is configured for an automatic transmission with a TRS input and detects a short to ground or an open in the TRS mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the odometer/trip odometer VFD will display all of its characters at once, then step through each character segment individually during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On vehicles with a TCM, the TCM continually monitors the TRS, then sends the proper message to the ElectroMechanical Instrument Cluster (EMIC). On vehicles without a TCM, the EMIC continually monitors the hard wired TRS multiplexed input. On vehicles with a TCM, for proper diagnosis of the TRS, the TCM, the EMIC, the CAN data bus or the electronic communication related to gear selector indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Description and Operation > Description Volt Meter Gauge: Description and Operation Description DESCRIPTION A voltage gauge is standard equipment on all instrument clusters. This gauge is located in the upper left quadrant of the instrument cluster, above the fuel gauge. This gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from L (or Low) to H (or High) for gasoline engines. On vehicles with a diesel engine, the scale reads from 8 to 18 volts. An International Control and Display Symbol icon for Battery Charging Condition is located on the cluster overlay, directly below the right end of the gauge scale. The voltage gauge graphics are black against a white field except for a single red graduation at each end of the gauge scale making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster general illumination lighting with the exterior lamps turned ON, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by a replaceable incandescent bulb and holder unit located on the instrument cluster electronic circuit board. The voltage gauge is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Description and Operation > Description > Page 16458 Volt Meter Gauge: Description and Operation Operation OPERATION The voltage gauge gives an indication to the vehicle operator of the electrical system voltage. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Controller Area Network (CAN) data bus. The voltage gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the left end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - System Voltage Message - Each time the cluster receives an electronic system voltage message from the PCM or ECM indicating the voltage is between about 9.5 volts and about 15 volts, the gauge needle is moved to the relative voltage position on the gauge scale. - System Voltage Low (Charge Fail) Message - Each time the cluster receives three consecutive electronic system voltage messages from the PCM or ECM indicating the voltage is less than about 9 volts (charge fail condition) or that the battery temperature sensor input is an open circuit, the gauge needle is moved to the graduation on the far left end of the gauge scale and the check gauges indicator is illuminated. The gauge needle remains at the far left end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a single message from the PCM or ECM indicating the voltage is greater than about 9.5 volts (but less than about 15.5 volts), or until the ignition switch is turned to the OFF position, whichever occurs first. On vehicles equipped with the optional diesel engine, the ECM is programmed to restrict the voltage gauge needle to a position above the graduation on the far left end of the gauge scale and suppress the check engine indicator operation until after the engine intake manifold air heater has completed a pre-heat or post-heat cycle. - System Voltage High Message - Each time the cluster receives 3 consecutive electronic system voltage messages from the PCM or ECM indicating the voltage is greater than about 15.5 volts, the gauge needle is moved to the graduation on the far right end of the gauge scale and the check gauges indicator is illuminated. The gauge needle remains at the right end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating the voltage is less than about 15.0 volts (but greater than about 9.5 volts), or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster fails to receive a system voltage message, it will hold the gauge needle at the last indication for about three seconds, or until the ignition switch is turned to the OFF position, whichever occurs first. After three seconds, the cluster will move the gauge needle to the far left end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the voltage gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM (gasoline engine) or ECM (diesel engine) continually monitors the system voltage to control the generator output. The PCM or ECM then sends the proper system voltage message to the ElectroMechanical Instrument Cluster (EMIC). If the instrument cluster turns ON the check gauges indicator due to a charge fail or voltage high condition, it may indicate that the charging system requires service. For proper diagnosis of the charging system, the PCM, the ECM, the EMIC, the CAN data bus or the electronic communication related to voltage gauge operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Water In Fuel Indicator > Water In Fuel Sensor > Component Information > Locations > Sensor-Water In Fuel Water In Fuel Sensor: Locations Sensor-Water In Fuel Component ID: 433 Component : SENSOR-WATER IN FUEL Connector: Name : SENSOR-WATER IN FUEL Color : BLACK # of pins : 2 Qualifier : (5.9L) A WATER IN FUEL SENSOR GROUND K923 18BR/WT B WATER IN FUEL SENSOR SIGNAL G123 18VT/LG Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Water In Fuel Indicator > Water In Fuel Sensor > Component Information > Locations > Sensor-Water In Fuel > Page 16464 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Water In Fuel Indicator > Water In Fuel Sensor > Component Information > Locations > Sensor-Water In Fuel > Page 16465 Connector: Name : SENSOR-WATER IN FUEL Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Water In Fuel Indicator > Water In Fuel Sensor > Component Information > Locations > Sensor-Water In Fuel > Page 16466 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Water In Fuel Indicator > Water In Fuel Sensor > Component Information > Locations > Sensor-Water In Fuel > Page 16467 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Water In Fuel Indicator > Water In Fuel Sensor > Component Information > Locations > Sensor-Water In Fuel > Page 16468 Water In Fuel Sensor: Locations Water - In - Fuel Sensor The WIF sensor (2) is located on the bottom of the fuel filter housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Water In Fuel Indicator > Water In Fuel Sensor > Component Information > Locations > Page 16469 Water In Fuel Sensor: Diagrams Component ID: 433 Component : SENSOR-WATER IN FUEL Connector: Name : SENSOR-WATER IN FUEL Color : BLACK # of pins : 2 Qualifier : (5.9L) A WATER IN FUEL SENSOR GROUND K923 18BR/WT B WATER IN FUEL SENSOR SIGNAL G123 18VT/LG Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Water In Fuel Indicator > Water In Fuel Sensor > Component Information > Locations > Page 16470 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Water In Fuel Indicator > Water In Fuel Sensor > Component Information > Locations > Page 16471 Connector: Name : SENSOR-WATER IN FUEL Color : # of pins : 2 Qualifier : (6.7L) Pin Description Circuit 1 SENSOR GROUND K914 18BR/WT 2 WATER IN FUEL SENSOR SIGNAL G123 18VT/LG Component Location - 18 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Water In Fuel Indicator > Water In Fuel Sensor > Component Information > Locations > Page 16472 Component Location - 14 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Water In Fuel Indicator > Water In Fuel Sensor > Component Information > Locations > Page 16473 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Water In Fuel Indicator > Water In Fuel Sensor > Component Information > Description and Operation > Description Water In Fuel Sensor: Description and Operation Description DESCRIPTION The Water-In-Fuel (WIF) sensor (2) is located on the bottom of the fuel filter/water separator canister (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Water In Fuel Indicator > Water In Fuel Sensor > Component Information > Description and Operation > Description > Page 16476 Water In Fuel Sensor: Description and Operation Operation OPERATION The sensor sends an input to the Engine Control Module (ECM) when it senses water in the fuel filter/water separator. As the water level in the filter/separator increases, the resistance across the WIF sensor decreases. This decrease in resistance is sent as a signal to the ECM and compared to a high water standard value. Once the value reaches 30 to 40 kilohms, the ECM will activate the water-in-fuel warning lamp through CCD bus circuits. This all takes place when the ignition key is initially put in the ON position. The ECM continues to monitor the input while the engine is running. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Water In Fuel Indicator > Water In Fuel Sensor > Component Information > Description and Operation > Page 16477 Water In Fuel Sensor: Service and Repair Water-In-Fuel (WIF) Sensor Replacement: The WIF sensor (2) is located on the bottom of the fuel filter housing. The WIF sensor is not a separately serviceable item. If diagnostics have led you to replace this sensor, then the whole fuel filter assembly (1) needs to be changed. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Component ID: 458 Component : SWITCH-BACKUP LAMP Connector: Name : SWITCH-BACKUP LAMP Color : BLACK # of pins : 2 Qualifier : (3.7L M/T/4.7L M/T) Pin Description Circuit 1 GROUND Z965 20BK 2 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 16483 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 16484 Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 16485 Connector: Name : SWITCH-BACKUP LAMP Color : BLACK # of pins : 2 Qualifier : (M/T 5.7L HD/DIESEL M/T) Pin Description Circuit 1 GROUND Z965 20BK 2 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 16486 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 16487 Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 16488 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 16489 Backup Lamp Switch: Diagrams Component ID: 458 Component : SWITCH-BACKUP LAMP Connector: Name : SWITCH-BACKUP LAMP Color : BLACK # of pins : 2 Qualifier : (3.7L M/T/4.7L M/T) Pin Description Circuit 1 GROUND Z965 20BK 2 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 16490 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 16491 Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 16492 Connector: Name : SWITCH-BACKUP LAMP Color : BLACK # of pins : 2 Qualifier : (M/T 5.7L HD/DIESEL M/T) Pin Description Circuit 1 GROUND Z965 20BK 2 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 16493 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 16494 Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 16495 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Description and Operation > Description Backup Lamp Switch: Description and Operation Description DESCRIPTION Vehicles equipped with a manual transmission have a normally open, spring-loaded plunger type backup lamp switch (2). Vehicles with an optional electronic automatic transmission have a Transmission Range Sensor (TRS) that is used to perform several functions, including that of the backup lamp switch. Refer to the service and diagnostic information for the automatic transmission type installed in the vehicle. The backup lamp switch is located in a threaded hole on the side of the manual transmission housing. The switch has a threaded body and a hex formation near the plunger end of the switch. An integral connector receptacle at the end of the switch opposite the plunger connects the switch to the vehicle electrical system through a take out and connector of the engine wire harness. When installed, only the switch connector and the hex formation are visible on the outside of the transmission housing. The backup lamp switch cannot be adjusted or repaired and, if ineffective or damaged, the entire switch unit must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Description and Operation > Description > Page 16498 Backup Lamp Switch: Description and Operation Operation OPERATION The backup lamp switch controls the flow of battery voltage to the backup lamp bulbs through an output on the backup lamp feed circuit. The switch plunger is mechanically actuated by the gearshift mechanism within the transmission, which will depress the switch plunger and close the switch contacts whenever the REVERSE gear has been selected. The switch receives battery voltage through a fuse in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run) circuit whenever the ignition switch is in the ON position. The backup lamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Description and Operation > Page 16499 Backup Lamp Switch: Testing and Inspection BACKUP LAMP SWITCH 1. Disconnect and isolate the battery negative cable. 2. Raise and support the vehicle. 3. Locate and disconnect the engine wire harness connector for the backup lamp switch. 4. Check for continuity between the two terminal pins in the backup lamp switch connector receptacle. a. With the gear selector lever in the REVERSE position, there should be continuity. b. With the gear selector lever in any position other than REVERSE, there should be no continuity. 5. If the switch fails either of these two continuity tests, replace the ineffective backup lamp switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Service and Repair > Removal Brake Light Bulb: Service and Repair Removal Bulb - Cab And Chassis BULB - CAB AND CHASSIS NOTE: The rear lamp unit contains two bulbs: the park/turn signal/brake/license plate, and the backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Disconnect and isolate the battery negative cable. 2. Remove the four screws (1) that secure the lens (2) to the rear lamp unit housing (5). 3. Push the backup lamp bulb (4), or the park/turn signal/brake/license plate bulb (7) slightly into its socket (3) or (6), then rotate the bulb counterclockwise about 30 degrees to unlock it. 4. Pull the base of the bulb straight out of the socket. Bulb - Pick-Up BULB - PICK-UP NOTE: The rear lamp unit contains two bulbs: park/stop/turn signal/side marker and backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Disconnect and isolate the battery negative cable. 2. Remove the rear lamp unit (1) from the end of the quarter panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Service and Repair > Removal > Page 16505 3. Disconnect the wire harness connector (3) from the park/stop/turn signal/side marker (2) or the backup (4) bulb socket on the back of the lamp housing. 4. Firmly grasp the socket on the back of the housing and rotate it counterclockwise about 30 degrees to unlock it. 5. Pull the socket and bulb straight out from the keyed opening in the housing. 6. Pull the base of the bulb straight out of the socket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Service and Repair > Removal > Page 16506 Brake Light Bulb: Service and Repair Installation Bulb - Cab And Chassis BULB - CAB AND CHASSIS CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: The rear lamp unit contains two bulbs: the park/turn signal/brake/license plate, and the backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Align the base of the backup lamp bulb (4), or the park/turn signal/brake/license plate lamp bulb (7) with its socket (3) or (6). 2. Push the bulb straight into the socket until the base is firmly seated, then rotate the bulb clockwise about 30 degrees to lock it into place. 3. Position the lens (2) to the rear lamp unit housing (5). 4. Install and tighten the four screws (1) that secure the lens to the housing. Tighten the screws to 2 Nm (20 in. lbs.). 5. Reconnect the battery negative cable. Bulb - Pick-Up BULB - PICK-UP CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Service and Repair > Removal > Page 16507 NOTE: The rear lamp unit contains two bulbs: park/stop/turn signal/side marker and backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Align the base of the bulb with the park/stop/turn signal/side marker (2) or the backup (4) bulb socket. 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of the rear lamp unit housing (1). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reconnect the wire harness connector (3) to the socket. 7. Reinstall the rear lamp unit onto the end of the quarter panel. 8. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Component ID: 488 Component : SWITCH-STOP LAMP Connector: Name : SWITCH-STOP LAMP Color : BLACK # of pins : 6 Pin Description Circuit 1 FUSED B(+) A103 18GY/RD 2 BRAKE LAMP SWITCH OUTPUT L50 18WT/TN 3 S/C BRAKE SWITCH OUTPUT V30 20VT/WT 4 BRAKE SWITCH NO. 2 SIGNAL V32 20VT/YL 5 GROUND Z429 20BK/OR 6 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT Component Location - 41 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 16511 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 16512 Brake Light Switch: Diagrams Component ID: 488 Component : SWITCH-STOP LAMP Connector: Name : SWITCH-STOP LAMP Color : BLACK # of pins : 6 Pin Description Circuit 1 FUSED B(+) A103 18GY/RD 2 BRAKE LAMP SWITCH OUTPUT L50 18WT/TN 3 S/C BRAKE SWITCH OUTPUT V30 20VT/WT 4 BRAKE SWITCH NO. 2 SIGNAL V32 20VT/YL 5 GROUND Z429 20BK/OR 6 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT Component Location - 41 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 16513 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Description Brake Light Switch: Description and Operation Description DESCRIPTION The brake lamp switch (2) is a three circuit, spring-loaded plunger actuated switch that is secured to the steering column support bracket under the instrument panel on the driver side of the vehicle. The molded plastic switch housing has an integral connector receptacle (1) containing six terminal pins and featuring a Connector Position Assurance (CPA) lock. The switch is connected to the vehicle electrical system through a dedicated take out of the instrument panel wire harness. The switch plunger (3) extends through a mounting collar (4) on one end of the switch housing. The plunger has a one time telescoping self-adjustment feature that is activated after the switch is installed by moving an adjustment release lever (5) on the opposite end of the switch housing clockwise, until it locks into a position that is horizontal and parallel to the connector receptacle. An installed brake lamp switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or removed from its mounting position for any reason, it must be replaced with a new unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Description > Page 16516 Brake Light Switch: Description and Operation Operation OPERATION The brake lamp switch controls three independent circuits. These circuits are described as follows: - Brake Lamp Switch Circuit - A normally open brake lamp switch circuit receives a battery voltage input, and supplies this battery voltage to the brake lamps and the Controller Antilock Brake (CAB) on a brake lamp switch output circuit only when the brake pedal is depressed (brake lamp switch plunger released). - Brake Lamp Switch Signal Circuit - A normally closed brake lamp switch signal circuit receives a direct path to ground, and supplies this ground input to the Powertrain Control Module (PCM) on a brake lamp switch sense circuit only when the brake pedal is released (brake lamp switch plunger is depressed). - Speed Control Circuit - A normally closed speed control circuit receives a battery voltage input from the Powertrain Control Module on a speed control supply circuit, and supplies this battery voltage to the speed control servo solenoids (dump, vacuum, and vent) on a speed control brake switch output circuit only when the speed control system is turned ON and the brake pedal is released (brake lamp switch plunger is depressed). The components of the self-adjusting brake switch plunger consist of a two-piece telescoping plunger, a split plunger locking collar, and a release wedge. The release lever has a shaft with a wedge that spreads the plunger locking collar to an open or released position. After the switch is installed and the brake pedal is released, the plunger telescopes to the correct adjustment position. When the release lever is moved to the release position, the wedge is disengaged from the locking collar causing the collar to apply a clamping pressure to the two plunger halves, fixing the plunger length. The brake lamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 16517 Brake Light Switch: Testing and Inspection BRAKE LAMP SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. CAUTION: Do not remove the brake lamp switch from the mounting bracket. The self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 2. Disconnect the wire harness connector from the brake lamp switch. 3. Using an ohmmeter, perform the continuity tests at the terminal pins (1) in the brake lamp switch connector receptacle as shown in the Brake Lamp Switch Tests table. 4. If the switch fails any of the continuity tests, replace the ineffective brake lamp switch as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Removal Brake Light Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Locate the brake lamp switch (2) near the support bracket on the lower steering column (1). 3. Disconnect the wire harness connector (3) from the brake lamp switch. 4. Rotate the brake lamp switch housing clockwise about 30 degrees to align the tabs on the switch locking collar with the keyed hole in the switch mounting bracket. 5. Pull the switch straight back from the keyed hole to remove it from the bracket. CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 6. Discard the removed brake lamp switch . Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Removal > Page 16520 Brake Light Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 1. Depress and hold the brake pedal in the depressed position. 2. Align the tabs on the brake lamp switch locking collar with the keyed hole in the switch mounting bracket on the lower steering column (1). 3. Insert the tabs on the brake lamp switch locking collar through the keyed hole in the switch mounting bracket until the switch housing (2) is firmly seated against the bracket. 4. Rotate the switch housing counterclockwise about 30 degrees to engage the tabs on the locking collar with the switch mounting bracket. CAUTION: Do not release or pull up on the brake pedal before the switch plunger adjustment has been completed. 5. Release the brake pedal, but do not pull it upward. 6. Rotate the plunger adjustment release lever (4) clockwise until it locks into place. The lever should be parallel to the brake lamp switch connector receptacle. This action will set the switch plunger length to a final adjustment position and cannot be undone. If not performed properly the first time, a new brake lamp switch must be installed. 7. Reconnect the wire harness connector (3) to the brake lamp switch. 8. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Locations Cargo Lamp: Locations Component ID: 176 Component : LAMP-HIGH MOUNTED STOP/CARGO Connector: Name : LAMP-HIGH MOUNTED STOP/CARGO Color : WHITE # of pins : 4 Pin Description Circuit 1 CARGO LAMP DRIVER L14 20WT/RD 2 GROUND Z964 20BK 3 GROUND Z964 20BK 4 BRAKE LAMP SWITCH OUTPUT L50 18WT/TN Component Location - 68 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Locations > Page 16524 Component Location - 53 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Locations > Page 16525 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Locations > Page 16526 Cargo Lamp: Diagrams Component ID: 176 Component : LAMP-HIGH MOUNTED STOP/CARGO Connector: Name : LAMP-HIGH MOUNTED STOP/CARGO Color : WHITE # of pins : 4 Pin Description Circuit 1 CARGO LAMP DRIVER L14 20WT/RD 2 GROUND Z964 20BK 3 GROUND Z964 20BK 4 BRAKE LAMP SWITCH OUTPUT L50 18WT/TN Component Location - 68 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Locations > Page 16527 Component Location - 53 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Locations > Page 16528 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair > Removal Cargo Lamp: Service and Repair Removal REMOVAL NOTE: The Center High Mounted Stop Lamp (CHMSL) may house up to three bulbs. The center bulb is the CHMSL bulb and illuminates through a red lens, while on vehicles so equipped the two outboard bulbs are for the cargo lamps and illuminate through clear lenses. The bulb types and service procedures are identical for all three of these bulbs. 1. Disconnect and isolate the battery negative cable. 2. Remove the two screws that secure the CHMSL to the rear cab roof header panel. 3. Pull the CHMSL lens and housing (1) away from the header panel far enough to access the lamp wiring and bulb sockets on the back of the lamp. 4. Firmly grasp either outboard socket (3) on the back of the lamp housing and rotate it counterclockwise about 30 degrees to unlock it. 5. Pull the socket and bulb straight out from the keyed opening in the housing. 6. Pull the base of the bulb (2) straight out of the socket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair > Removal > Page 16531 Cargo Lamp: Service and Repair Installation INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: The Center High Mounted Stop Lamp (CHMSL) may house up to three bulbs. The center bulb is the CHMSL bulb and illuminates through a red lens, while on vehicles so equipped the two outboard bulbs are for the cargo lamps and illuminate through clear lenses. The bulb types and service procedures are identical for all three of these bulbs. 1. Align the base of the bulb (2) with the socket (3). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with either keyed outboard opening on the back of CHMSL housing (1). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Position the CHMSL into the opening in the rear cab roof header panel. 7. Install and tighten the two screws (passenger side first) that secure the CHMSL to the header panel. Tighten the screws to 2 Nm (20 in. lbs.). 8. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Bulb > Component Information > Service and Repair > Removal Center Mounted Brake Lamp Bulb: Service and Repair Removal BULB NOTE: The Center High Mounted Stop Lamp (CHMSL) may house up to three bulbs. The center bulb is the CHMSL bulb and illuminates through a red lens, while on vehicles so equipped the two outboard bulbs are for the cargo lamps and illuminate through clear lenses. The bulb types and service procedures are identical for all three of these bulbs. 1. Disconnect and isolate the battery negative cable. 2. Remove the two screws that secure the CHMSL to the rear cab roof header panel. 3. Pull the CHMSL lens and housing (1) away from the header panel far enough to access the lamp wiring and bulb sockets (3) on the back of the lamp. 4. Firmly grasp the center socket on the back of the lamp housing and rotate it counterclockwise about 30 degrees to unlock it. 5. Pull the socket and bulb straight out from the keyed opening in the housing. 6. Pull the base of the bulb (2) straight out of the socket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Bulb > Component Information > Service and Repair > Removal > Page 16537 Center Mounted Brake Lamp Bulb: Service and Repair Installation BULB CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: The Center High Mounted Stop Lamp (CHMSL) may house up to three bulbs. The center bulb is the CHMSL bulb and illuminates through a red lens, while on vehicles so equipped the two outboard bulbs are for the cargo lamps and illuminate through clear lenses. The bulb types and service procedures are identical for all three of these bulbs. 1. Align the base of the CHMSL bulb (2) with the socket (3). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of CHMSL housing (1). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Position the CHMSL into the opening in the rear cab roof header panel. 7. Install and tighten the two screws (passenger side first) that secure the CHMSL to the header panel. Tighten the screws to 2 Nm (20 in. lbs.). 8. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Clearance Lamp > Clearance Lamp Bulb > Component Information > Service and Repair > Removal Clearance Lamp Bulb: Service and Repair Removal BULB 1. Disconnect and isolate the battery negative cable. 2. Remove the cab clearance lamp (1) from the roof panel. 3. Pull the base of the bulb (3) straight out of the socket (2). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Clearance Lamp > Clearance Lamp Bulb > Component Information > Service and Repair > Removal > Page 16543 Clearance Lamp Bulb: Service and Repair Installation BULB CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. 1. Align the base of the bulb (3) with the socket (2). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Reinstall the cab clearance lamp (1) onto the roof panel. 4. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Technical Service Bulletins > Lighting - Information On Exterior Lamp Lens Fogging Cornering Lamp: Technical Service Bulletins Lighting - Information On Exterior Lamp Lens Fogging NUMBER: 23-035-07 GROUP: Body DATE: August 08, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-041-06, DATED SEPTEMBER 27, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Exterior Lamp - Lens Fogging MODELS: 2006 - 2008 (CS) Pacifica 2006 - 2008 (DC/DM) Ram Truck - Cab & Chassis (3500/4500/5500) 2006 - 2008 (DR/DH/D1) Ram Truck - Pick-up (1500/2500/3500) 2006 - 2008 (HB/HG) Durango/Aspen 2007 - 2008 (JK) Wrangler 2006 (JR) Stratus/Sebring 2006 - 2007 (JR27) Sebring Convertible 2007 - 2008 (JS) Sebring/Avenger 2008 (JS27) Sebring Convertible 2007 - 2008 (KA) Nitro 2006 - 2007 (KJ) Liberty/Cherokee 2008 (KK) Liberty/Cherokee 2006 - 2008 (LX/LE) 300/Magnum/Charger 2007 - 2008 (MK49) Compass 2007 - 2008 (MK74) Patriot 2006 - 2008 (ND) Dakota 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) PT Cruiser 2006 - 2007 (RS/RG) Town & Country/Caravan/Voyager 2008 (RT) Town & Country/Caravan/Voyager 2006-2008 (WK/WH) Grand Cherokee 2006 - 2008 (XK/XH) Commander DISCUSSION: Some customers may report that on occasion, vehicle exterior lamp assemblies are fogged with a light layer of condensation on the inside of the lenses. This may be reported after the lamps have been turned on and brought up to operating temperature, turned off, and then rapidly cooled by cold water (such as rain, or the water from a car wash). Lens fogging can also occur under certain atmospheric conditions after a vehicle has been parked outside overnight (i.e., a warm humid day followed by clear cool night). This will usually clear as atmospheric conditions change to allow the condensation to change back into a vapor. Turning the lamps on will usually accelerate this process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Technical Service Bulletins > Lighting - Information On Exterior Lamp Lens Fogging > Page 16548 A lamp that has large amounts of water droplets visible on most internal surfaces indicates a problem with the lamp sealing that has allowed water to enter the lamp. In this instance, the customer is likely to report that moisture in the lamp is always present and never disappears. A lamp that exhibits internal moisture permanently should be replaced. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams Console Lamp: Diagrams Component ID: 158 Component : LAMP-CENTER CONSOLE Connector: Name : LAMP-CENTER CONSOLE Color : # of pins : 2 Qualifier : (LOWER BUCKET) Gender : FEMALE Pin Description Circuit 1 GROUND Z939 18BK 2 GLOVE BOX LAMP DRIVER M228 18YL/LB Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information > Service and Repair > Removal Courtesy Lamp Bulb: Service and Repair Removal BULB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove the center bezel lamp unit (4) from the instrument panel center support structure. 3. Depress the latch tab (2) and slide the hood (1) off of the end of the lamp housing. 4. Pull the base of the bulb (3) straight out of the bulb holder within the lamp housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information > Service and Repair > Removal > Page 16557 Courtesy Lamp Bulb: Service and Repair Installation BULB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. 1. Align the base of the center bezel lamp bulb (3) with the bulb holder within the lamp housing (4). 2. Push the bulb straight into the bulb holder until the base is firmly seated. 3. Slide the hood (1) over the end of the lamp housing until the latch tab (2) snaps into place. 4. Reinstall the lamp unit into the instrument panel center support structure. 5. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Locations Glove Box Lamp: Locations Component ID: 173 Component : LAMP-GLOVE BOX Connector: Name : LAMP-GLOVE BOX Color : BLACK # of pins : 2 Pin Description Circuit 1 GROUND Z328 20BK/TN 2 GLOVE BOX LAMP DRIVER M228 20YL/LB Component Location - 46 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Locations > Page 16561 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Locations > Page 16562 Glove Box Lamp: Diagrams Component ID: 173 Component : LAMP-GLOVE BOX Connector: Name : LAMP-GLOVE BOX Color : BLACK # of pins : 2 Pin Description Circuit 1 GROUND Z328 20BK/TN 2 GLOVE BOX LAMP DRIVER M228 20YL/LB Component Location - 46 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Locations > Page 16563 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Service and Repair > Removal Glove Box Lamp: Service and Repair Removal Bulb BULB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Open the glove box door. 3. Reach through the window (3) in the instrument panel glove box opening (1) to access the bulb on the side of the glove box lamp and switch unit (2). 4. Pull the base of the bulb straight out of the bulb holder. Lamp/Switch LAMP/SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Service and Repair > Removal > Page 16566 1. Disconnect and isolate the battery negative cable. 2. Open the glove box door. 3. Reach through the window in the instrument panel (2) glove box opening behind the switch to access and depress the retaining latch on either side of the glove box lamp and switch unit (3). 4. While holding the retaining latch depressed, push the glove box lamp and switch unit out through the mounting hole in the face of the instrument panel. 5. Disconnect the wire harness connector (1) from the glove box lamp and switch. 6. Remove the lamp and switch unit from the instrument panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Service and Repair > Removal > Page 16567 Glove Box Lamp: Service and Repair Installation Bulb BULB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. 1. Reach through the window (3) in the instrument panel glove box opening (1) to align the base of the bulb with the bulb holder on the side of the glove box lamp and switch unit (2). 2. Push the bulb straight into the bulb holder until the base is firmly seated. 3. Close the glove box door. 4. Reconnect the battery negative cable. Lamp/Switch LAMP/SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Service and Repair > Removal > Page 16568 1. Position the glove box lamp and switch unit (3) to the instrument panel (2) glove box opening. 2. Reconnect the wire harness connector (1) to the lamp and switch unit. 3. Feed the wire harness back through the switch mounting hole. 4. Align the lamp and switch unit with the mounting hole in the instrument panel. 5. Using hand pressure, push the lamp and switch unit firmly and evenly into the mounting hole until it is fully seated. 6. Close the glove box door. 7. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Service and Repair > Removal Glove Box Lamp Switch: Service and Repair Removal LAMP/SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Open the glove box door. 3. Reach through the window in the instrument panel (2) glove box opening behind the switch to access and depress the retaining latch on either side of the glove box lamp and switch unit (3). 4. While holding the retaining latch depressed, push the glove box lamp and switch unit out through the mounting hole in the face of the instrument panel. 5. Disconnect the wire harness connector (1) from the glove box lamp and switch. 6. Remove the lamp and switch unit from the instrument panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Service and Repair > Removal > Page 16573 Glove Box Lamp Switch: Service and Repair Installation LAMP/SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the glove box lamp and switch unit (3) to the instrument panel (2) glove box opening. 2. Reconnect the wire harness connector (1) to the lamp and switch unit. 3. Feed the wire harness back through the switch mounting hole. 4. Align the lamp and switch unit with the mounting hole in the instrument panel. 5. Using hand pressure, push the lamp and switch unit firmly and evenly into the mounting hole until it is fully seated. 6. Close the glove box door. 7. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Technical Service Bulletins > Lighting - Information On Exterior Lamp Lens Fogging Daytime Running Lamp: Technical Service Bulletins Lighting - Information On Exterior Lamp Lens Fogging NUMBER: 23-035-07 GROUP: Body DATE: August 08, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-041-06, DATED SEPTEMBER 27, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Exterior Lamp - Lens Fogging MODELS: 2006 - 2008 (CS) Pacifica 2006 - 2008 (DC/DM) Ram Truck - Cab & Chassis (3500/4500/5500) 2006 - 2008 (DR/DH/D1) Ram Truck - Pick-up (1500/2500/3500) 2006 - 2008 (HB/HG) Durango/Aspen 2007 - 2008 (JK) Wrangler 2006 (JR) Stratus/Sebring 2006 - 2007 (JR27) Sebring Convertible 2007 - 2008 (JS) Sebring/Avenger 2008 (JS27) Sebring Convertible 2007 - 2008 (KA) Nitro 2006 - 2007 (KJ) Liberty/Cherokee 2008 (KK) Liberty/Cherokee 2006 - 2008 (LX/LE) 300/Magnum/Charger 2007 - 2008 (MK49) Compass 2007 - 2008 (MK74) Patriot 2006 - 2008 (ND) Dakota 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) PT Cruiser 2006 - 2007 (RS/RG) Town & Country/Caravan/Voyager 2008 (RT) Town & Country/Caravan/Voyager 2006-2008 (WK/WH) Grand Cherokee 2006 - 2008 (XK/XH) Commander DISCUSSION: Some customers may report that on occasion, vehicle exterior lamp assemblies are fogged with a light layer of condensation on the inside of the lenses. This may be reported after the lamps have been turned on and brought up to operating temperature, turned off, and then rapidly cooled by cold water (such as rain, or the water from a car wash). Lens fogging can also occur under certain atmospheric conditions after a vehicle has been parked outside overnight (i.e., a warm humid day followed by clear cool night). This will usually clear as atmospheric conditions change to allow the condensation to change back into a vapor. Turning the lamps on will usually accelerate this process. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Technical Service Bulletins > Lighting - Information On Exterior Lamp Lens Fogging > Page 16578 A lamp that has large amounts of water droplets visible on most internal surfaces indicates a problem with the lamp sealing that has allowed water to enter the lamp. In this instance, the customer is likely to report that moisture in the lamp is always present and never disappears. A lamp that exhibits internal moisture permanently should be replaced. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Technical Service Bulletins > Page 16579 Daytime Running Lamp: Description and Operation Vehicles manufactured for sale in Canada illuminate the high beam filament of both headlamp bulbs at a reduced intensity when the engine is running, the parking brakes are released and the exterior lamps are turned off. The TIPM must be programmed with the appropriately for this feature to be enabled. Once enabled, anytime the TIPM receives electronic messages over the CAN data bus from the PCM indicating the engine is running and from the EMIC indicating the status of the headlamp switch exterior lighting input is Off, the TIPM See: Maintenance/Fuses and Circuit Breakers/Fuse/Locationsprovides a pulse width modulated voltage output to the proper headlamp bulb filaments through the right and left high beam feed circuits to produce illumination at a reduced intensity. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair > Removal Dome Lamp Bulb: Service and Repair Removal Dual Lamp - Bulb DUAL LAMP - BULB 1. Disconnect and isolate the battery negative cable. 2. Remove the dome lamp (2) from the headliner. 3. With the lamp lens (1) in the open position, carefully unsnap the bulb (3) from the two bulb holders within the dome lamp housing. Single Lamp - Bulb SINGLE LAMP - BULB NOTE: There are two types of single lamp dome lamps available in this vehicle: one with a switch that is activated by depressing the lamp lens, and one without a switch. The bulb types and service procedures are identical for both of these lamps. 1. Disconnect and isolate the battery negative cable. 2. Insert the tip of a small flat-bladed screwdriver into the notch on one side of the dome lamp between the lens (4) and the lamp housing (1). 3. Gently pry the notched edge of the lens downward until it unsnaps from the housing. 4. Swing the notched end of the lens downward far enough to access the bulb (3). 5. Carefully unsnap the bulb from the two bulb holders within the dome lamp housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair > Removal > Page 16585 Dome Lamp Bulb: Service and Repair Installation Dual Lamp - Bulb DUAL LAMP - BULB CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. 1. With the dome lamp lens (1) in the open position, align the ends of the bulb (3) with the two bulb holders within the dome lamp housing (2). 2. Carefully press the bulb firmly and evenly into the bulb holders until it snaps into place. 3. Reinstall the lamp into the headliner. 4. Reconnect the battery negative cable. Single Lamp - Bulb SINGLE LAMP - BULB CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: There are two types of single lamp dome lamps available in this vehicle: one with a switch that is activated by depressing the lamp lens, and one without a switch. The bulb types and service procedures are identical for both of these lamps. 1. Align the ends of the bulb (3) with the two bulb holders within the dome lamp housing (1). 2. Carefully press the bulb firmly and evenly into the bulb holders until it snaps into place. 3. Swing the notched end of the lens (4) up into position against the housing, then press upward on the lens firmly and evenly until it snaps into the Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair > Removal > Page 16586 housing. 4. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Description and Operation > Description Door Switch: Description and Operation Description DESCRIPTION This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if ineffective or damaged, the door latch unit must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Description and Operation > Description > Page 16591 Door Switch: Description and Operation Operation OPERATION The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper electronic door ajar switch status messages to other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. The door ajar switches as well as the hard wired inputs and outputs of the switches may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair > Removal Fog/Driving Lamp Bulb: Service and Repair Removal BULB CAUTION: Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result. 1. Disconnect and isolate the battery negative cable. 2. Reach under and behind the front fascia to access the front fog lamp housing (1) on the back of the front bumper (4). 3. Disconnect the wire harness connector (3) from the fog lamp bulb (2). 4. Firmly grasp the bulb on the back of the housing and rotate it counterclockwise about 30 degrees to unlock it. 5. Pull the bulb straight out from the keyed opening in the housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair > Removal > Page 16597 Fog/Driving Lamp Bulb: Service and Repair Installation BULB CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. CAUTION: Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result. 1. Align the fog lamp bulb (2) with the keyed opening on the back of the front fog lamp housing (1). 2. Insert the bulb into the housing until it is firmly seated. 3. Rotate the bulb clockwise about 30 degrees to lock it into place. The bulb connector receptacle should be pointed straight downward. 4. Reconnect the wire harness connector (3) to the bulb. 5. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Indicator > Component Information > Description and Operation > Description Fog/Driving Lamp Indicator: Description and Operation Description DESCRIPTION A fog lamp indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with optional fog lamps, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The fog lamp indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Front Fog Light in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A green Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in green through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The fog lamp indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Indicator > Component Information > Description and Operation > Description > Page 16602 Fog/Driving Lamp Indicator: Description and Operation Operation OPERATION The fog lamp indicator gives an indication to the vehicle operator whenever the optional fog lamps are illuminated. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The fog lamp indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will allow this indicator to operate whenever the instrument cluster receives a battery current input on the fused B(+) circuit. Therefore, the LED can be illuminated regardless of the ignition switch position. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the fog lamp indicator for the following reasons: - Fog Indicator Lamp-On Message - Each time the cluster receives an electronic fog indicator lamp-ON message from the TIPM indicating the fog lamp circuit is energized, the fog lamp indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the exterior lamp load shedding (battery saver) timed interval expires, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the fog lamp indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors electronic exterior lighting switch status messages from the ElectroMechanical Instrument Cluster (EMIC) to determine the appropriate outputs to the fog lamps. The TIPM activates or deactivates the fog lamp circuit then sends the proper lamp-ON or lamp-OFF message back to the EMIC. For proper diagnosis of the fog lamp system, the TIPM, the EMIC, the CAN data bus or the electronic communication related to fog lamp indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Application and ID Hazard Warning Flasher: Application and ID Please Note: The Flasher function for this vehicle is provided by the Body Control Module. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Removal Headlamp Bulb: Service and Repair Removal BULB - HEADLAMP CAUTION: Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result. 1. Disconnect and isolate the battery negative cable. 2. Remove the front lamp unit (1) from the front fender. 3. Firmly grasp the headlamp bulb (2) on the back of the front lamp unit housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the bulb straight out from the keyed opening in the housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Removal > Page 16612 Headlamp Bulb: Service and Repair Installation BULB - HEADLAMP CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. CAUTION: Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result. 1. Align the headlamp bulb (2) with the keyed opening on the back of the front lamp unit housing (1). 2. Insert the bulb into the housing until it is firmly seated. 3. Rotate the bulb clockwise about 30 degrees to lock it into place. 4. Reinstall the front lamp unit onto the front fender. 5. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Component ID: 466 Component : SWITCH-HEADLAMP Connector: Name : SWITCH-HEADLAMP Color : BLACK # of pins : 10 Pin Description Circuit 1 HEADLAMP/FOG LAMP SWITCH SIGNAL L116 20WT/LG 2 PANEL LAMPS DIMMER SIGNAL E2 20OR/BR 3 HEADLAMP SWITCH RETURN L115 20WT/YL 4 HEADLAMP SWITCH DIMMER SIGNAL E19 20OR/BR 5 GROUND Z407 20BK/OR 6 CARGO LAMP SWITCH SIGNAL L914 20WT/LG 7-- 8-9-10 - Component Location - 44 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 16616 Component Location - 50 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 16617 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 16618 Headlamp Switch: Diagrams Component ID: 466 Component : SWITCH-HEADLAMP Connector: Name : SWITCH-HEADLAMP Color : BLACK # of pins : 10 Pin Description Circuit 1 HEADLAMP/FOG LAMP SWITCH SIGNAL L116 20WT/LG 2 PANEL LAMPS DIMMER SIGNAL E2 20OR/BR 3 HEADLAMP SWITCH RETURN L115 20WT/YL 4 HEADLAMP SWITCH DIMMER SIGNAL E19 20OR/BR 5 GROUND Z407 20BK/OR 6 CARGO LAMP SWITCH SIGNAL L914 20WT/LG 7-- 8-9-10 - Component Location - 44 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 16619 Component Location - 50 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 16620 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation > Description Headlamp Switch: Description and Operation Description DESCRIPTION The headlamp switch (1) is located on the instrument panel, to the left of the steering column. Two different switches are used. The standard switch features a three-position rotary knob (4) for exterior lighting control, a thumbwheel (2) for panel lamps dimming and interior lighting control, and a momentary push button (3) for cargo lamp control. An optional switch has a momentary PUSH function added to the rotary knob for front fog lamp control. Each of these switches is constructed of molded plastic. The rotary knob is molded plastic and knurled around its circumference to ease operator control. The thumbwheel is also plastic and knurled. On vehicles with optional fog lamps the rotary knob also has the text PUSH and an International Control and Display Symbol icon for Front Fog Light applied to it. The cargo lamp push button is plastic with a smooth finish and the text CARGO applied to it. The switch face plate is also labeled with graphics and icons to clearly identify the many functions of the rotary knob and thumbwheel. Three screws secure the switch to the back of the cluster bezel through integral mounting flanges that are molded to each side of the switch housing. The back of the switch housing has an integral connector receptacle containing terminal pins that connect the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. A panel dimmer controlled incandescent bulb soldered to the circuit board within the switch provides back lighting for visibility at night, but is not serviceable. The headlamp switch cannot be repaired and, if ineffective or damaged, it must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation > Description > Page 16623 Headlamp Switch: Description and Operation Operation OPERATION The headlamp switch uses two resistor multiplexed outputs and one conventional output to control the many functions and features it provides. The switch receives a clean ground from the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a headlamp switch return circuit. It then provides outputs to the EMIC on a headlamp switch signal circuit to control exterior lighting functions, on a panel lamps dimmer signal circuit to control panel dimmer and interior lighting functions, and on a cargo lamp return circuit to control the cargo lamps. The switch illumination circuit receives a path to ground at all times through the left instrument panel ground circuit. The illumination level is controlled by a Pulse-Width Modulated (PWM) output received from the EMIC on a headlamp switch illumination control circuit. The EMIC controls this output based upon the dimmer signal select mux input from the headlamp switch. The headlamp switch operates as follows: - Cargo Lamps Control - The cargo lamp push button on the headlamp switch is depressed to activate or deactivate the cargo lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by providing the appropriate cargo lighting control outputs through its internal cargo lamp driver circuit. Front Fog Lamps Control - For vehicles so equipped, the rotary knob on the headlamp switch is depressed to activate or deactivate the optional front fog lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic fog lamp switch status messages to the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The TIPM responds by energizing or de-energizing the front fog lamps and by sending an electronic message back to the EMIC to control the front fog lamp indicator. - Exterior Lighting Control - The rotary knob on the headlamp switch is rotated to a detent position to activate or deactivate the exterior lighting. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic exterior lighting switch status messages to the TIPM over the CAN data bus. The TIPM responds by energizing or de-energizing the park lamp and the high or low beam headlamp circuits, and by sending an electronic message back to the EMIC to control the high beam indicator. The TIPM also remembers which headlamp beams were last selected with the multi-function switch, and energizes those beams by default the next time the headlamps are turned ON. - Interior Lighting Control - The thumbwheel on the headlamp switch is rotated to the dome DEFEAT, dome ON, PARADE mode, or one of the six panel dimmer detent positions to control the interior courtesy/dome and panel lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by providing the appropriate interior lighting control outputs through its internal courtesy lamp driver circuits, electronic dimming level messages to other modules over the CAN data bus, and the proper PWM outputs to control dimming levels through several panel dimmer illumination control driver circuits. The headlamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation > Page 16624 Headlamp Switch: Testing and Inspection HEADLAMP SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Remove the cluster bezel from the instrument panel. 2. Disconnect the wire harness connector from the back of the headlamp switch. 3. Using an ohmmeter, test the resistance or continuity between the terminals of the switch as shown in the Headlamp Switch Tests table. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation > Page 16625 4. If the switch fails any of the tests, replace the ineffective headlamp switch as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair > Removal Headlamp Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel (1) from the instrument panel. 3. Disconnect the wire harness connector (3) from the back of the headlamp switch (4). 4. Place the cluster bezel face down on a suitable work surface. Be certain to take the proper precautions to protect the face of the bezel from cosmetic damage. 5. Remove the three screws (2) that secure the headlamp switch to the back of the cluster bezel. 6. Remove the headlamp switch from the cluster bezel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair > Removal > Page 16628 Headlamp Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the headlamp switch (4) to the back of the cluster bezel (1). 2. Install and tighten the three screws (2) that secure the headlamp switch to the cluster bezel. Tighten the screws to 2 Nm (20 in. lbs.). 3. Position the cluster bezel close enough to the instrument panel to reconnect the wire harness connector (3) to the back of the headlamp switch. 4. Reinstall the cluster bezel onto the instrument panel. 5. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Description and Operation > Description Hi-Beam Indicator Lamp: Description and Operation Description DESCRIPTION A high beam indicator is standard equipment on all instrument clusters. This indicator is located near the upper edge of the instrument cluster, between the tachometer and the speedometer. The high beam indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for High Beam in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A blue Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in blue through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The high beam indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Description and Operation > Description > Page 16633 Hi-Beam Indicator Lamp: Description and Operation Operation OPERATION The high beam indicator gives an indication to the vehicle operator whenever the headlamp high beams are illuminated. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and a hard wired multiplex input received by the cluster from the headlamp beam select switch circuitry of the multi-function switch on the washer/beam select switch mux circuit. The high beam indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will allow this indicator to operate whenever the instrument cluster receives a battery current input on the fused B(+) circuit. Therefore, the LED can be illuminated regardless of the ignition switch position. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the high beam indicator for the following reasons: - High Beam Headlamps-On Input - Each time the cluster detects a high beam headlamps-ON input from the headlamp beam select switch circuitry of the multi-function switch on the washer/beam select switch MUX circuit, the headlamp high beams and the high beam indicator will be illuminated. The indicator remains illuminated until the cluster receives a high beam headlamps-OFF input from the multi-function switch, or until the exterior lamp load shedding (battery saver) timed interval expires, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the high beam indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The ElectroMechanical Instrument Cluster (EMIC) continually monitors the headlamp switch and the multi-function switch to determine the proper headlamp low beam and high beam control. The EMIC then sends the proper electronic low beam and high beam lamp-ON and lamp-OFF messages to the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus and controls the high beam indicator operation accordingly. The hard wired headlamp switch and multi-function switch inputs and circuits related to high beam indicator operation may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. For proper diagnosis of the TIPM, the EMIC, the CAN data bus or the electronic communication related to high beam indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Dodge Ram Trucks from 2006 to 2009, do not use a horn relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 16638 Horn Relay: Description and Operation Dodge Ram Trucks from 2006 to 2009, do not use a horn relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Diagrams Horn Switch: Diagrams Component ID: 470 Component : SWITCH-HORN Connector: Name : SWITCH-HORN Color : WHITE # of pins : 2 Pin Description Circuit 1 HORN SWITCH SENSE X3 20DG/VT 2-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Diagrams > Page 16642 Horn Switch: Description and Operation DESCRIPTION The horn switch is serviced as a unit with the driver airbag trim cover. The horn switch can not be serviced separately. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information > Service and Repair > Removal License Plate Bulb: Service and Repair Removal BULB NOTE: This procedure is for vehicles with a pick-up bed only. On cab and chassis vehicles the license plate lamp is integral to the left rear lamp unit. The park/brake/turn signal bulb within the left rear lamp unit provides illumination for the license plate lamp function on all cab and chassis vehicles. 1. Disconnect and isolate the battery negative cable. 2. Reach under the rear bumper near the center to access the back of either of the two license plate lamp housings (3). 3. Firmly grasp the socket (2) on the back of the housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb (1) straight out from the keyed opening in the housing. 5. Pull the base of the bulb straight out of the socket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information > Service and Repair > Removal > Page 16648 License Plate Bulb: Service and Repair Installation BULB CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: This procedure is for vehicles with a pick-up bed only. On cab and chassis vehicles the license plate lamp is integral to the left rear lamp unit. The park/brake/turn signal bulb within the left rear lamp unit provides illumination for the license plate lamp function on all cab and chassis vehicles. 1. Align the base of the bulb (1) with the license plate lamp socket (2). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of the license plate lamp housing (3). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair > Removal Map Light Bulb: Service and Repair Removal Bulb - With Sunroof BULB - WITH SUNROOF NOTE: On vehicles equipped with an optional overhead console the standard front dome lamp is replaced by two combination dome and reading lamps that are integral to the console housing. Each of these lamps is controlled by the door ajar switches on the courtesy lamp circuit, but also are independently controlled by a switch that is activated by depressing the lamp lens. The bulb types and service procedures are identical for both of these lamps. NOTE: The overhead console reading lamp switches and bulb holders are serviced as a unit with the overhead console wire harness. 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console (3) from the headliner. 3. Firmly grasp the back of the reading lamp bulb socket (1) and unsnap it from the overhead console lamp housing. 4. Pull the socket and bulb (2) straight out from the keyed opening in the lamp housing. 5. Pull the base of the bulb straight out of the socket. Bulb - Without Sunroof BULB - WITHOUT SUNROOF NOTE: On vehicles equipped with an optional overhead console the standard front dome lamp is replaced by two combination dome and reading lamps that are integral to the console housing. Each of these lamps is controlled by the door ajar switches on the courtesy lamp circuit, but also are independently controlled by a switch that is activated by depressing the lamp lens. The bulb types and service procedures are identical for both of these lamps. NOTE: The overhead console reading lamp switches and bulb holders are serviced as a unit with the overhead console wire harness. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair > Removal > Page 16654 1. Disconnect and isolate the battery negative cable. 2. Using a small thin-bladed screwdriver, gently pry between each side of the lamp lens and the overhead console housing (1) to unsnap the pivot tabs (3) on the lens from the pivots in the lamp housing. 3. With the lens disengaged from both pivots, pull the front of the lens forward far enough to disengage the tab (2) on the rear edge of the lens from the slot in the rear of the overhead console lamp housing. 4. Remove the lens from the housing. 5. Carefully unsnap the bulb (2) from the two bulb holders (1) within the overhead console lamp housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair > Removal > Page 16655 Map Light Bulb: Service and Repair Installation Bulb - With Sunroof BULB - WITH SUNROOF CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: On vehicles equipped with an optional overhead console the standard front dome lamp is replaced by two combination dome and reading lamps that are integral to the console housing. Each of these lamps is controlled by the door ajar switches on the courtesy lamp circuit, but also are independently controlled by a switch that is activated by depressing the lamp lens. The bulb types and service procedures are identical for both of these lamps. NOTE: The overhead console reading lamp switches and bulb holders are serviced as a unit with the overhead console wire harness. 1. Align the base of the overhead console reading lamp bulb (2) with the socket (1). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of lamp housing in the overhead console. 4. Insert the socket and bulb into the housing and press firmly on the back of the socket until it snaps into place and is firmly seated. 5. Reinstall the overhead console onto the headliner. 6. Reconnect the battery negative cable. Bulb - Without Sunroof BULB - WITHOUT SUNROOF CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: On vehicles equipped with an optional overhead console the standard front dome lamp is replaced by two combination dome and reading lamps that are integral to the console housing. Each of these lamps is controlled by the door ajar switches on the courtesy lamp circuit, but also are independently controlled by a switch that is activated by depressing the lamp lens. The bulb types and service procedures are identical for both of these lamps. NOTE: The overhead console reading lamp switches and bulb holders are serviced as a unit with the overhead console wire harness. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair > Removal > Page 16656 1. Align the ends of the bulb (2) with the two bulb holders (1) within the overhead console lamp housing. 2. Carefully press the bulb firmly and evenly into the bulb holders until it snaps into place. 3. Position the lens tab (2) into the slot in the rear of the overhead console (1) lamp housing. 4. Align the pivot tabs (3) on each side of the lens with the pivots within the overhead console lamp housing. 5. Press firmly and evenly on the lens over both pivot locations until both pivot tabs snap back onto the pivots within the housing. 6. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Front Lamp Unit Marker Lamp Bulb: Service and Repair Front Lamp Unit Removal BULB - FRONT SIDE MARKER 1. Disconnect and isolate the battery negative cable. 2. Remove the front lamp unit (1) from the front fender. 3. Firmly grasp the front side marker bulb socket (5) on the back of the front lamp unit housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb straight out from the keyed opening in the housing. 5. Pull the base of the bulb straight out of the socket. Installation BULB - FRONT SIDE MARKER CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. 1. Align the base of the bulb with the front side marker bulb socket (5). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of the front lamp unit housing (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Front Lamp Unit > Page 16662 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reinstall the front lamp unit onto the front fender. 7. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Front Lamp Unit > Page 16663 Marker Lamp Bulb: Service and Repair Lamp-Marker Bulb - Rear Fender BULB - REAR FENDER NOTE: These lamps are used on vehicles with a pick-up bed and dual rear wheels only. A lamp with an amber lens is located on the rear fender ahead of each rear wheel opening, and a lamp with a red lens is located on the rear fender behind each rear wheel opening. The bulb types and service procedures are identical for all four of these lamps. 1. Disconnect and isolate the battery negative cable. 2. Using hand pressure, press the rear edge of the rear fender marker lamp lens/housing (4) toward the front of the vehicle against the spring pressure of the retaining clip, then pull the rear edge of the lamp outward to disengage it from the mounting hole in the rear fender. 3. Pull the lamp out from the rear fender far enough to access the bulb socket (1) on the back of the lamp lens/housing. 4. Firmly grasp the bulb socket on the back of the lamp lens/housing and rotate it counterclockwise about 30 degrees to unlock it. 5. Pull the socket and bulb straight out from the keyed opening in the housing. 6. Pull the base of the bulb (3) straight out of the socket. Bulb - Tailgate BULB - TAILGATE NOTE: This lamp is used on vehicles with a pick-up bed and dual rear wheels only. A lamp with a red lens and containing three bulbs is located on the rearward facing surface of the pick-up bed sill below the tailgate. The bulb types and service procedures are identical for all three of these bulbs. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Front Lamp Unit > Page 16664 1. Disconnect and isolate the battery negative cable. 2. Remove the two screws that secure the outboard ends of the tailgate marker lamp lens/housing (1) to the rearward facing surface of the sill panel. 3. Pull the marker lamp out from the sill panel far enough to access the sockets (3) on the bottom of the lamp housing. 4. Firmly grasp the marker lamp socket on the bottom of the lamp housing and rotate it counterclockwise about 30 degrees to unlock it. 5. Pull the socket and bulb (2) straight out from the keyed opening in the housing. 6. Pull the base of the bulb straight out of the socket. Bulb - Rear Fender BULB - REAR FENDER CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: These lamps are used on vehicles with a pick-up bed and dual rear wheels only. A lamp with an amber lens is located on the rear fender ahead of each rear wheel opening, and a lamp with a red lens is located on the rear fender behind each rear wheel opening. The bulb types and service procedures are identical for all four of these lamps. 1. Align the base of the bulb (3) with the socket (1). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Be certain that a rubber O-ring seal (2) is properly installed and in good condition around the base of the bulb socket. 4. Align the socket and bulb with the keyed opening on the back of the rear fender marker lamp lens/housing (4). 5. Insert the socket and bulb into the housing until the socket is firmly seated. 6. Rotate the socket clockwise about 30 degrees to lock it into place. 7. Engage the front edge of the marker lamp into the front edge of the mounting hole in the rear fender. 8. Using hand pressure, press the rear edge of the marker lamp lens/housing toward the front of the vehicle against the spring pressure of the retaining clip, then push the rear edge of the lamp into the rear of the mounting hole in the rear fender. 9. Reconnect the battery negative cable. Bulb - Tailgate BULB - TAILGATE CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Front Lamp Unit > Page 16665 NOTE: This lamp is used on vehicles with a pick-up bed and dual rear wheels only. A lamp with a red lens and containing three bulbs is located on the rearward facing surface of the pick-up bed sill below the tailgate. The bulb types and service procedures are identical for all three of these bulbs. 1. Align the base of the bulb (2) with the socket (3). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the bottom of the tailgate marker lamp lens/housing (1). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Position the marker lamp to the outer surface of the sill panel. 7. Install and tighten the two screws that secure the marker lamp lens/housing to the tailgate panel. Tighten the screws to 2 Nm (20 in. lbs.). 8. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Dodge Ram Trucks, 2006-2009 all, do not use a parking lamp relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 16670 Parking Lamp Relay: Description and Operation Dodge Ram Trucks, 2006-2009 all, do not use a parking lamp relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair > Removal Parking Light Bulb: Service and Repair Removal BULB - PARK/TURN SIGNAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front lamp unit (1) from the front fender. 3. Firmly grasp the park/turn signal bulb socket (3) on the back of the front lamp unit housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb straight out from the keyed opening in the housing. 5. Pull the base of the bulb (2) straight out of the socket (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair > Removal > Page 16675 Parking Light Bulb: Service and Repair Installation BULB - PARK/TURN SIGNAL CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. 1. Align the base of the bulb (2) with the park/turn signal bulb socket (1). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb (3) with the keyed opening on the back of the front lamp unit housing (1). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reinstall the front lamp unit onto the front fender. 7. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Dodge Ram Trucks from 2006 to 2009, do not use a horn relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 16680 Horn Relay: Description and Operation Dodge Ram Trucks from 2006 to 2009, do not use a horn relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Dodge Ram Trucks, 2006-2009 all, do not use a parking lamp relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 16684 Parking Lamp Relay: Description and Operation Dodge Ram Trucks, 2006-2009 all, do not use a parking lamp relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Dodge Ram Trucks, 2006-2009 all,Trailer Tow lamp relay is not serviceable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 16688 Trailer Lighting Relay: Diagrams Dodge Ram Trucks, 2006-2009 all, do not use a trailer tow relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Component ID: 458 Component : SWITCH-BACKUP LAMP Connector: Name : SWITCH-BACKUP LAMP Color : BLACK # of pins : 2 Qualifier : (3.7L M/T/4.7L M/T) Pin Description Circuit 1 GROUND Z965 20BK 2 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 16693 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 16694 Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 16695 Connector: Name : SWITCH-BACKUP LAMP Color : BLACK # of pins : 2 Qualifier : (M/T 5.7L HD/DIESEL M/T) Pin Description Circuit 1 GROUND Z965 20BK 2 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 16696 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 16697 Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 16698 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 16699 Backup Lamp Switch: Diagrams Component ID: 458 Component : SWITCH-BACKUP LAMP Connector: Name : SWITCH-BACKUP LAMP Color : BLACK # of pins : 2 Qualifier : (3.7L M/T/4.7L M/T) Pin Description Circuit 1 GROUND Z965 20BK 2 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 16700 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 16701 Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 16702 Connector: Name : SWITCH-BACKUP LAMP Color : BLACK # of pins : 2 Qualifier : (M/T 5.7L HD/DIESEL M/T) Pin Description Circuit 1 GROUND Z965 20BK 2 FUSED IGNITION SWITCH OUTPUT (RUN) L10 20WT/GY Component Location - 22 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 16703 Component Location - 24 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 16704 Component Location - 25 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 16705 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Description and Operation > Description Backup Lamp Switch: Description and Operation Description DESCRIPTION Vehicles equipped with a manual transmission have a normally open, spring-loaded plunger type backup lamp switch (2). Vehicles with an optional electronic automatic transmission have a Transmission Range Sensor (TRS) that is used to perform several functions, including that of the backup lamp switch. Refer to the service and diagnostic information for the automatic transmission type installed in the vehicle. The backup lamp switch is located in a threaded hole on the side of the manual transmission housing. The switch has a threaded body and a hex formation near the plunger end of the switch. An integral connector receptacle at the end of the switch opposite the plunger connects the switch to the vehicle electrical system through a take out and connector of the engine wire harness. When installed, only the switch connector and the hex formation are visible on the outside of the transmission housing. The backup lamp switch cannot be adjusted or repaired and, if ineffective or damaged, the entire switch unit must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Description and Operation > Description > Page 16708 Backup Lamp Switch: Description and Operation Operation OPERATION The backup lamp switch controls the flow of battery voltage to the backup lamp bulbs through an output on the backup lamp feed circuit. The switch plunger is mechanically actuated by the gearshift mechanism within the transmission, which will depress the switch plunger and close the switch contacts whenever the REVERSE gear has been selected. The switch receives battery voltage through a fuse in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run) circuit whenever the ignition switch is in the ON position. The backup lamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Description and Operation > Page 16709 Backup Lamp Switch: Testing and Inspection BACKUP LAMP SWITCH 1. Disconnect and isolate the battery negative cable. 2. Raise and support the vehicle. 3. Locate and disconnect the engine wire harness connector for the backup lamp switch. 4. Check for continuity between the two terminal pins in the backup lamp switch connector receptacle. a. With the gear selector lever in the REVERSE position, there should be continuity. b. With the gear selector lever in any position other than REVERSE, there should be no continuity. 5. If the switch fails either of these two continuity tests, replace the ineffective backup lamp switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Component ID: 488 Component : SWITCH-STOP LAMP Connector: Name : SWITCH-STOP LAMP Color : BLACK # of pins : 6 Pin Description Circuit 1 FUSED B(+) A103 18GY/RD 2 BRAKE LAMP SWITCH OUTPUT L50 18WT/TN 3 S/C BRAKE SWITCH OUTPUT V30 20VT/WT 4 BRAKE SWITCH NO. 2 SIGNAL V32 20VT/YL 5 GROUND Z429 20BK/OR 6 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT Component Location - 41 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 16713 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 16714 Brake Light Switch: Diagrams Component ID: 488 Component : SWITCH-STOP LAMP Connector: Name : SWITCH-STOP LAMP Color : BLACK # of pins : 6 Pin Description Circuit 1 FUSED B(+) A103 18GY/RD 2 BRAKE LAMP SWITCH OUTPUT L50 18WT/TN 3 S/C BRAKE SWITCH OUTPUT V30 20VT/WT 4 BRAKE SWITCH NO. 2 SIGNAL V32 20VT/YL 5 GROUND Z429 20BK/OR 6 BRAKE SWITCH NO. 1 SIGNAL B29 20DG/WT Component Location - 41 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 16715 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Description Brake Light Switch: Description and Operation Description DESCRIPTION The brake lamp switch (2) is a three circuit, spring-loaded plunger actuated switch that is secured to the steering column support bracket under the instrument panel on the driver side of the vehicle. The molded plastic switch housing has an integral connector receptacle (1) containing six terminal pins and featuring a Connector Position Assurance (CPA) lock. The switch is connected to the vehicle electrical system through a dedicated take out of the instrument panel wire harness. The switch plunger (3) extends through a mounting collar (4) on one end of the switch housing. The plunger has a one time telescoping self-adjustment feature that is activated after the switch is installed by moving an adjustment release lever (5) on the opposite end of the switch housing clockwise, until it locks into a position that is horizontal and parallel to the connector receptacle. An installed brake lamp switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or removed from its mounting position for any reason, it must be replaced with a new unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Description > Page 16718 Brake Light Switch: Description and Operation Operation OPERATION The brake lamp switch controls three independent circuits. These circuits are described as follows: - Brake Lamp Switch Circuit - A normally open brake lamp switch circuit receives a battery voltage input, and supplies this battery voltage to the brake lamps and the Controller Antilock Brake (CAB) on a brake lamp switch output circuit only when the brake pedal is depressed (brake lamp switch plunger released). - Brake Lamp Switch Signal Circuit - A normally closed brake lamp switch signal circuit receives a direct path to ground, and supplies this ground input to the Powertrain Control Module (PCM) on a brake lamp switch sense circuit only when the brake pedal is released (brake lamp switch plunger is depressed). - Speed Control Circuit - A normally closed speed control circuit receives a battery voltage input from the Powertrain Control Module on a speed control supply circuit, and supplies this battery voltage to the speed control servo solenoids (dump, vacuum, and vent) on a speed control brake switch output circuit only when the speed control system is turned ON and the brake pedal is released (brake lamp switch plunger is depressed). The components of the self-adjusting brake switch plunger consist of a two-piece telescoping plunger, a split plunger locking collar, and a release wedge. The release lever has a shaft with a wedge that spreads the plunger locking collar to an open or released position. After the switch is installed and the brake pedal is released, the plunger telescopes to the correct adjustment position. When the release lever is moved to the release position, the wedge is disengaged from the locking collar causing the collar to apply a clamping pressure to the two plunger halves, fixing the plunger length. The brake lamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 16719 Brake Light Switch: Testing and Inspection BRAKE LAMP SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. CAUTION: Do not remove the brake lamp switch from the mounting bracket. The self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 2. Disconnect the wire harness connector from the brake lamp switch. 3. Using an ohmmeter, perform the continuity tests at the terminal pins (1) in the brake lamp switch connector receptacle as shown in the Brake Lamp Switch Tests table. 4. If the switch fails any of the continuity tests, replace the ineffective brake lamp switch as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Removal Brake Light Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Locate the brake lamp switch (2) near the support bracket on the lower steering column (1). 3. Disconnect the wire harness connector (3) from the brake lamp switch. 4. Rotate the brake lamp switch housing clockwise about 30 degrees to align the tabs on the switch locking collar with the keyed hole in the switch mounting bracket. 5. Pull the switch straight back from the keyed hole to remove it from the bracket. CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 6. Discard the removed brake lamp switch . Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Removal > Page 16722 Brake Light Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 1. Depress and hold the brake pedal in the depressed position. 2. Align the tabs on the brake lamp switch locking collar with the keyed hole in the switch mounting bracket on the lower steering column (1). 3. Insert the tabs on the brake lamp switch locking collar through the keyed hole in the switch mounting bracket until the switch housing (2) is firmly seated against the bracket. 4. Rotate the switch housing counterclockwise about 30 degrees to engage the tabs on the locking collar with the switch mounting bracket. CAUTION: Do not release or pull up on the brake pedal before the switch plunger adjustment has been completed. 5. Release the brake pedal, but do not pull it upward. 6. Rotate the plunger adjustment release lever (4) clockwise until it locks into place. The lever should be parallel to the brake lamp switch connector receptacle. This action will set the switch plunger length to a final adjustment position and cannot be undone. If not performed properly the first time, a new brake lamp switch must be installed. 7. Reconnect the wire harness connector (3) to the brake lamp switch. 8. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Combination Switch: Locations Component ID: 472 Component : SWITCH-MULTIFUNCTION Connector: Name : SWITCH-MULTIFUNCTION Color : BLACK # of pins : 4 Pin Description Circuit 1 WASH/BEAM SELECT SWITCH SIGNAL G194 20VT/LG 2 WIPER/TURN/BEAM SELECT SWITCH RETURN L900 20WT/YL 3 TURN LAMPS SWITCH SIGNAL L12 20WT/OR 4 INTERMITTENT WIPER SWITCH SIGNAL W52 20BR/YL Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 16726 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 16727 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 16728 Combination Switch: Diagrams Component ID: 472 Component : SWITCH-MULTIFUNCTION Connector: Name : SWITCH-MULTIFUNCTION Color : BLACK # of pins : 4 Pin Description Circuit 1 WASH/BEAM SELECT SWITCH SIGNAL G194 20VT/LG 2 WIPER/TURN/BEAM SELECT SWITCH RETURN L900 20WT/YL 3 TURN LAMPS SWITCH SIGNAL L12 20WT/OR 4 INTERMITTENT WIPER SWITCH SIGNAL W52 20BR/YL Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 16729 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 16730 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Description Combination Switch: Description and Operation Description DESCRIPTION The multi-function switch (3) is located on the steering column, just below the steering wheel. The only visible components of the multi-function switch are the control stalk (2) and control knob (1) that extend through the steering column shrouds on the left side of the column, and the hazard warning push button (4) that extends through the shroud on the top of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator (5) are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. Three integral locating posts on the switch housing, one on the top and two on the bottom, slide into channels in a receptacle on the left side of the multi-function switch mounting housing near the top of the steering column to ensure proper positioning of the switch. Then two screws secure the switch to the mounting housing. A single integral connector receptacle containing four terminal pins on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The multi-function switch provides the vehicle operator with a control interface for the following functions: - Hazard Warning Control - The multi-function switch hazard warning push button provides two detent positions (ON and OFF) to control the hazard warning lamps. Headlamp Beam Selection - The multi-function switch control stalk provides detent switching for selection of the headlamp HIGH or LOW beams. There is also an intermediate momentary position that allows the headlamp high beam circuits to be momentarily flashed to provide an optical horn feature (sometimes referred to as flash-to-pass) as an optical signalling device. - Turn Signal Control - The multi-function switch control stalk provides momentary non-detent (lane change) switching or detent switching with automatic cancellation for both the left and right turn signal lamps. - Washer Control - The multi-function switch control knob provides a momentary WASH position for washer system operation. - Wiper Control - The multi-function switch control knob provides two continuous wipe switch positions, LOW speed or HIGH speed; and an intermittent wipe mode with five delay interval positions. The multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch must be replaced as a unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Description > Page 16733 Combination Switch: Description and Operation Operation OPERATION The multi-function switch uses resistor multiplexing to control the many functions and features it provides using only three hard wired output circuits. The switch receives a clean ground from the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a multi-function switch return circuit. It then provides outputs to the EMIC on a wash/beam select switch signal circuit to control washer and headlamp beam selection, on an intermittent wiper switch signal circuit to control wipers, and on a turn lamps switch signal circuit to control turn signal and hazard warning functions. The multi-function switch operates as follows: - Hazard Warning Control - The hazard warning push button of the multi-function switch is depressed to activate the hazard warning system, and depressed again to turn the system OFF. When the push button is actuated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic hazard switch status messages to the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The TIPM then energizes and flashes or de-energizes both the left and right turn signal circuits to provide the visual hazard warning. - Headlamp Beam Selection - The control stalk of the multi-function switch is pulled towards the steering wheel past a detent to actuate the integral beam select switch circuitry, or to an intermediate, momentary position before the detent to actuate the optical horn feature. Each time the control stalk is actuated to a detent position, the opposite headlamp beam from what is currently selected will be energized. Each time the control stalk is actuated to the momentary position with the headlamps turned OFF, the headlamp high beams will be illuminated for as long as the control stalk is held in this position. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic beam select switch status messages to the TIPM over the CAN data bus. The TIPM energizes or de-energizes the selected LOW or HIGH beam circuits. - Turn Signal Control - The control stalk of the multi-function switch is moved upward to activate the RIGHT turn signal circuitry, and, downward to activate the LEFT turn signal circuitry. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, the cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the LEFT turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. When a turn signal is activated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic turn signal switch status messages to the TIPM over the CAN data bus. The TIPM energizes and flashes or de-energizes the selected left or right turn signal circuits. - Washer Control - The control knob on the end of the multi-function switch control stalk is depressed towards the steering column to momentarily activate the washer pump in the WASH mode. The washer pump will continue to operate in the washer mode until the control knob is released. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic washer switch status messages to the TIPM over the CAN data bus. The TIPM responds by energizing or de-energizing the washer pump in the washer mode. - Wiper Control - The control knob on the end of the multi-function switch control stalk is rotated to one of the continuous wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the wiper mode. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic wiper switch status messages to the TIPM over the CAN data bus. The TIPM responds by energizing or de-energizing the wiper motor. The TIPM is programmed to operate the wiper motor at the selected low or high continuous wipe speed, and to provide the selected electronically controlled speed-sensitive intermittent wipe or wipe-after-wash mode features. The multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Page 16734 Combination Switch: Testing and Inspection MULTI-FUNCTION SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Remove the multi-function switch from the switch mounting housing on the steering column. 2. Disconnect the wire harness connector from the back of the multi-function switch. 3. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the Multi-Function Switch Tests table. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Page 16735 4. If the switch fails any of the tests, replace the ineffective multi-function switch as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Removal Combination Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag from the steering wheel. 3. Disconnect the steering wheel wire harness connectors from the upper clockspring connector receptacles. CAUTION: Be certain that the screws that secure the steering wheel puller to the steering wheel are fully engaged in the steering wheel armature without passing through the steering wheel and damaging the clockspring. 4. Remove the steering wheel from the steering column. 5. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 6. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 7. Using hand pressure, press inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 8. Remove the upper shroud from the lower shroud and the steering column. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Removal > Page 16738 9. Remove the one center screw that secures the lower shroud to the steering column (4). 10. Remove the lower shroud from the steering column. 11. Disconnect the wire harness connector (2) from the back of the multi-function switch housing (1). 12. Remove the two screws (4) that secure the switch to the multi-function switch mounting housing (3). 13. Grasp the switch control stalk and pull it toward the left side of the vehicle to remove the switch from the mounting housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Removal > Page 16739 Combination Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Slide the multi-function switch (1) into the multi-function switch mounting housing (3) from the left side. Be certain that the alignment pins on the top and bottom of the switch are properly engaged in the channels of the mounting housing. 2. Install and tighten the two screws (4) that secure the switch to the mounting housing. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the back of the switch housing. 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Removal > Page 16740 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). NOTE: When reinstalling the steering wheel, be certain to index the yellow rubber booted engagement dowel on the upper surface of the clockspring rotor between the two fins cast into the lower surface of the steering wheel armature hub. 10. Reinstall the steering wheel onto the steering column. 11. Reconnect the steering wheel wire harness connectors to the upper clockspring connector receptacles. Be certain that the steering wheel wire harness is routed between the steering wheel back trim cover and the steering wheel armature. 12. Reinstall the driver airbag onto the steering wheel. 13. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Description and Operation > Description Door Switch: Description and Operation Description DESCRIPTION This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if ineffective or damaged, the door latch unit must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Description and Operation > Description > Page 16745 Door Switch: Description and Operation Operation OPERATION The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper electronic door ajar switch status messages to other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. The door ajar switches as well as the hard wired inputs and outputs of the switches may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair > Removal Glove Box Lamp Switch: Service and Repair Removal LAMP/SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Open the glove box door. 3. Reach through the window in the instrument panel (2) glove box opening behind the switch to access and depress the retaining latch on either side of the glove box lamp and switch unit (3). 4. While holding the retaining latch depressed, push the glove box lamp and switch unit out through the mounting hole in the face of the instrument panel. 5. Disconnect the wire harness connector (1) from the glove box lamp and switch. 6. Remove the lamp and switch unit from the instrument panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair > Removal > Page 16750 Glove Box Lamp Switch: Service and Repair Installation LAMP/SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the glove box lamp and switch unit (3) to the instrument panel (2) glove box opening. 2. Reconnect the wire harness connector (1) to the lamp and switch unit. 3. Feed the wire harness back through the switch mounting hole. 4. Align the lamp and switch unit with the mounting hole in the instrument panel. 5. Using hand pressure, push the lamp and switch unit firmly and evenly into the mounting hole until it is fully seated. 6. Close the glove box door. 7. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Component ID: 466 Component : SWITCH-HEADLAMP Connector: Name : SWITCH-HEADLAMP Color : BLACK # of pins : 10 Pin Description Circuit 1 HEADLAMP/FOG LAMP SWITCH SIGNAL L116 20WT/LG 2 PANEL LAMPS DIMMER SIGNAL E2 20OR/BR 3 HEADLAMP SWITCH RETURN L115 20WT/YL 4 HEADLAMP SWITCH DIMMER SIGNAL E19 20OR/BR 5 GROUND Z407 20BK/OR 6 CARGO LAMP SWITCH SIGNAL L914 20WT/LG 7-- 8-9-10 - Component Location - 44 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 16754 Component Location - 50 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 16755 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 16756 Headlamp Switch: Diagrams Component ID: 466 Component : SWITCH-HEADLAMP Connector: Name : SWITCH-HEADLAMP Color : BLACK # of pins : 10 Pin Description Circuit 1 HEADLAMP/FOG LAMP SWITCH SIGNAL L116 20WT/LG 2 PANEL LAMPS DIMMER SIGNAL E2 20OR/BR 3 HEADLAMP SWITCH RETURN L115 20WT/YL 4 HEADLAMP SWITCH DIMMER SIGNAL E19 20OR/BR 5 GROUND Z407 20BK/OR 6 CARGO LAMP SWITCH SIGNAL L914 20WT/LG 7-- 8-9-10 - Component Location - 44 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 16757 Component Location - 50 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 16758 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Description Headlamp Switch: Description and Operation Description DESCRIPTION The headlamp switch (1) is located on the instrument panel, to the left of the steering column. Two different switches are used. The standard switch features a three-position rotary knob (4) for exterior lighting control, a thumbwheel (2) for panel lamps dimming and interior lighting control, and a momentary push button (3) for cargo lamp control. An optional switch has a momentary PUSH function added to the rotary knob for front fog lamp control. Each of these switches is constructed of molded plastic. The rotary knob is molded plastic and knurled around its circumference to ease operator control. The thumbwheel is also plastic and knurled. On vehicles with optional fog lamps the rotary knob also has the text PUSH and an International Control and Display Symbol icon for Front Fog Light applied to it. The cargo lamp push button is plastic with a smooth finish and the text CARGO applied to it. The switch face plate is also labeled with graphics and icons to clearly identify the many functions of the rotary knob and thumbwheel. Three screws secure the switch to the back of the cluster bezel through integral mounting flanges that are molded to each side of the switch housing. The back of the switch housing has an integral connector receptacle containing terminal pins that connect the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. A panel dimmer controlled incandescent bulb soldered to the circuit board within the switch provides back lighting for visibility at night, but is not serviceable. The headlamp switch cannot be repaired and, if ineffective or damaged, it must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Description > Page 16761 Headlamp Switch: Description and Operation Operation OPERATION The headlamp switch uses two resistor multiplexed outputs and one conventional output to control the many functions and features it provides. The switch receives a clean ground from the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a headlamp switch return circuit. It then provides outputs to the EMIC on a headlamp switch signal circuit to control exterior lighting functions, on a panel lamps dimmer signal circuit to control panel dimmer and interior lighting functions, and on a cargo lamp return circuit to control the cargo lamps. The switch illumination circuit receives a path to ground at all times through the left instrument panel ground circuit. The illumination level is controlled by a Pulse-Width Modulated (PWM) output received from the EMIC on a headlamp switch illumination control circuit. The EMIC controls this output based upon the dimmer signal select mux input from the headlamp switch. The headlamp switch operates as follows: - Cargo Lamps Control - The cargo lamp push button on the headlamp switch is depressed to activate or deactivate the cargo lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by providing the appropriate cargo lighting control outputs through its internal cargo lamp driver circuit. Front Fog Lamps Control - For vehicles so equipped, the rotary knob on the headlamp switch is depressed to activate or deactivate the optional front fog lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic fog lamp switch status messages to the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The TIPM responds by energizing or de-energizing the front fog lamps and by sending an electronic message back to the EMIC to control the front fog lamp indicator. - Exterior Lighting Control - The rotary knob on the headlamp switch is rotated to a detent position to activate or deactivate the exterior lighting. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic exterior lighting switch status messages to the TIPM over the CAN data bus. The TIPM responds by energizing or de-energizing the park lamp and the high or low beam headlamp circuits, and by sending an electronic message back to the EMIC to control the high beam indicator. The TIPM also remembers which headlamp beams were last selected with the multi-function switch, and energizes those beams by default the next time the headlamps are turned ON. - Interior Lighting Control - The thumbwheel on the headlamp switch is rotated to the dome DEFEAT, dome ON, PARADE mode, or one of the six panel dimmer detent positions to control the interior courtesy/dome and panel lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by providing the appropriate interior lighting control outputs through its internal courtesy lamp driver circuits, electronic dimming level messages to other modules over the CAN data bus, and the proper PWM outputs to control dimming levels through several panel dimmer illumination control driver circuits. The headlamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Page 16762 Headlamp Switch: Testing and Inspection HEADLAMP SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Remove the cluster bezel from the instrument panel. 2. Disconnect the wire harness connector from the back of the headlamp switch. 3. Using an ohmmeter, test the resistance or continuity between the terminals of the switch as shown in the Headlamp Switch Tests table. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Page 16763 4. If the switch fails any of the tests, replace the ineffective headlamp switch as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Removal Headlamp Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel (1) from the instrument panel. 3. Disconnect the wire harness connector (3) from the back of the headlamp switch (4). 4. Place the cluster bezel face down on a suitable work surface. Be certain to take the proper precautions to protect the face of the bezel from cosmetic damage. 5. Remove the three screws (2) that secure the headlamp switch to the back of the cluster bezel. 6. Remove the headlamp switch from the cluster bezel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Removal > Page 16766 Headlamp Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the headlamp switch (4) to the back of the cluster bezel (1). 2. Install and tighten the three screws (2) that secure the headlamp switch to the cluster bezel. Tighten the screws to 2 Nm (20 in. lbs.). 3. Position the cluster bezel close enough to the instrument panel to reconnect the wire harness connector (3) to the back of the headlamp switch. 4. Reinstall the cluster bezel onto the instrument panel. 5. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams Horn Switch: Diagrams Component ID: 470 Component : SWITCH-HORN Connector: Name : SWITCH-HORN Color : WHITE # of pins : 2 Pin Description Circuit 1 HORN SWITCH SENSE X3 20DG/VT 2-- Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 16770 Horn Switch: Description and Operation DESCRIPTION The horn switch is serviced as a unit with the driver airbag trim cover. The horn switch can not be serviced separately. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair > Removal Tail Light Bulb: Service and Repair Removal Bulb - Cab And Chassis BULB - CAB AND CHASSIS NOTE: The rear lamp unit contains two bulbs: the park/turn signal/brake/license plate, and the backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Disconnect and isolate the battery negative cable. 2. Remove the four screws (1) that secure the lens (2) to the rear lamp unit housing (5). 3. Push the backup lamp bulb (4), or the park/turn signal/brake/license plate bulb (7) slightly into its socket (3) or (6), then rotate the bulb counterclockwise about 30 degrees to unlock it. 4. Pull the base of the bulb straight out of the socket. Bulb - Pick-Up BULB - PICK-UP NOTE: The rear lamp unit contains two bulbs: park/stop/turn signal/side marker and backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Disconnect and isolate the battery negative cable. 2. Remove the rear lamp unit (1) from the end of the quarter panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair > Removal > Page 16776 3. Disconnect the wire harness connector (3) from the park/stop/turn signal/side marker (2) or the backup (4) bulb socket on the back of the lamp housing. 4. Firmly grasp the socket on the back of the housing and rotate it counterclockwise about 30 degrees to unlock it. 5. Pull the socket and bulb straight out from the keyed opening in the housing. 6. Pull the base of the bulb straight out of the socket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair > Removal > Page 16777 Tail Light Bulb: Service and Repair Installation Bulb - Cab And Chassis BULB - CAB AND CHASSIS CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: The rear lamp unit contains two bulbs: the park/turn signal/brake/license plate, and the backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Align the base of the backup lamp bulb (4), or the park/turn signal/brake/license plate lamp bulb (7) with its socket (3) or (6). 2. Push the bulb straight into the socket until the base is firmly seated, then rotate the bulb clockwise about 30 degrees to lock it into place. 3. Position the lens (2) to the rear lamp unit housing (5). 4. Install and tighten the four screws (1) that secure the lens to the housing. Tighten the screws to 2 Nm (20 in. lbs.). 5. Reconnect the battery negative cable. Bulb - Pick-Up BULB - PICK-UP CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair > Removal > Page 16778 NOTE: The rear lamp unit contains two bulbs: park/stop/turn signal/side marker and backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Align the base of the bulb with the park/stop/turn signal/side marker (2) or the backup (4) bulb socket. 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of the rear lamp unit housing (1). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reconnect the wire harness connector (3) to the socket. 7. Reinstall the rear lamp unit onto the end of the quarter panel. 8. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16783 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16784 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16785 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16786 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16787 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16788 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16789 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16790 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16791 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16792 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16793 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16794 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16795 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16796 Trailer Lamps: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16797 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16798 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16799 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 16800 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Description and Operation > Description Trailer Lamps: Description and Operation Description DESCRIPTION The rear body wire harness on the rear frame (1) of all vehicles is equipped with a take out with a standard, light-duty 4-pin trailer tow connector (2) that is secured to the top of the trailer hitch platform (4) behind the rear bumper. Vehicles equipped with an optional factory-installed trailer towing package have a second take out with a connector (3) that plugs into a receptacle in the back of a heavy duty, sealed, 7-pin trailer tow connector that is located near the center of the rear bumper. Vehicles equipped with the trailer tow package also include an electric trailer brake wiring provision that terminates at a connector located on top of the large body harness connection under the instrument panel to the left of the brake pedal, as well as an electric trailer brake pigtail harness and an instruction card (1) that are stored in the glove box (2) when the vehicle is shipped from the factory. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Description and Operation > Description > Page 16803 Trailer Lamps: Description and Operation Operation OPERATION The standard 4-pin trailer tow connector contains the following vehicle circuits: park/tail lamps, left stop/turn lamp, right stop/turn lamp, and ground. The optional trailer towing package 7-way connector contains the same circuits as the 4-pin connector plus the following additional circuits: backup lamp, trailer battery and electric brake. If an aftermarket electric brake controller is used, the electric brake pigtail harness supplied will make installation easier. The connection (blue 4-way connector) for the harness is located under the instrument panel to the left of the brake pedal on top of the large body harness connection. Refer to the appropriate wiring information. The battery line of this harness may be used to charge the trailer battery. However, a battery isolation unit is not supplied and the trailer battery may discharge the vehicle battery while the engine is not running. The battery line is protected by a fuse or a circuit breaker. Refer to the owner's manual in the vehicle glove box for type, location, and ampere rating of the fuse or circuit breaker. The trailer tow connectors as well as the hard wired inputs and outputs of the connectors may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Dodge Ram Trucks, 2006-2009 all,Trailer Tow lamp relay is not serviceable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 16807 Trailer Lighting Relay: Diagrams Dodge Ram Trucks, 2006-2009 all, do not use a trailer tow relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations Combination Switch: Locations Component ID: 472 Component : SWITCH-MULTIFUNCTION Connector: Name : SWITCH-MULTIFUNCTION Color : BLACK # of pins : 4 Pin Description Circuit 1 WASH/BEAM SELECT SWITCH SIGNAL G194 20VT/LG 2 WIPER/TURN/BEAM SELECT SWITCH RETURN L900 20WT/YL 3 TURN LAMPS SWITCH SIGNAL L12 20WT/OR 4 INTERMITTENT WIPER SWITCH SIGNAL W52 20BR/YL Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 16812 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 16813 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 16814 Combination Switch: Diagrams Component ID: 472 Component : SWITCH-MULTIFUNCTION Connector: Name : SWITCH-MULTIFUNCTION Color : BLACK # of pins : 4 Pin Description Circuit 1 WASH/BEAM SELECT SWITCH SIGNAL G194 20VT/LG 2 WIPER/TURN/BEAM SELECT SWITCH RETURN L900 20WT/YL 3 TURN LAMPS SWITCH SIGNAL L12 20WT/OR 4 INTERMITTENT WIPER SWITCH SIGNAL W52 20BR/YL Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 16815 Component Location - 42 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 16816 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Description and Operation > Description Combination Switch: Description and Operation Description DESCRIPTION The multi-function switch (3) is located on the steering column, just below the steering wheel. The only visible components of the multi-function switch are the control stalk (2) and control knob (1) that extend through the steering column shrouds on the left side of the column, and the hazard warning push button (4) that extends through the shroud on the top of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator (5) are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. Three integral locating posts on the switch housing, one on the top and two on the bottom, slide into channels in a receptacle on the left side of the multi-function switch mounting housing near the top of the steering column to ensure proper positioning of the switch. Then two screws secure the switch to the mounting housing. A single integral connector receptacle containing four terminal pins on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The multi-function switch provides the vehicle operator with a control interface for the following functions: - Hazard Warning Control - The multi-function switch hazard warning push button provides two detent positions (ON and OFF) to control the hazard warning lamps. Headlamp Beam Selection - The multi-function switch control stalk provides detent switching for selection of the headlamp HIGH or LOW beams. There is also an intermediate momentary position that allows the headlamp high beam circuits to be momentarily flashed to provide an optical horn feature (sometimes referred to as flash-to-pass) as an optical signalling device. - Turn Signal Control - The multi-function switch control stalk provides momentary non-detent (lane change) switching or detent switching with automatic cancellation for both the left and right turn signal lamps. - Washer Control - The multi-function switch control knob provides a momentary WASH position for washer system operation. - Wiper Control - The multi-function switch control knob provides two continuous wipe switch positions, LOW speed or HIGH speed; and an intermittent wipe mode with five delay interval positions. The multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch must be replaced as a unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Description and Operation > Description > Page 16819 Combination Switch: Description and Operation Operation OPERATION The multi-function switch uses resistor multiplexing to control the many functions and features it provides using only three hard wired output circuits. The switch receives a clean ground from the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a multi-function switch return circuit. It then provides outputs to the EMIC on a wash/beam select switch signal circuit to control washer and headlamp beam selection, on an intermittent wiper switch signal circuit to control wipers, and on a turn lamps switch signal circuit to control turn signal and hazard warning functions. The multi-function switch operates as follows: - Hazard Warning Control - The hazard warning push button of the multi-function switch is depressed to activate the hazard warning system, and depressed again to turn the system OFF. When the push button is actuated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic hazard switch status messages to the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The TIPM then energizes and flashes or de-energizes both the left and right turn signal circuits to provide the visual hazard warning. - Headlamp Beam Selection - The control stalk of the multi-function switch is pulled towards the steering wheel past a detent to actuate the integral beam select switch circuitry, or to an intermediate, momentary position before the detent to actuate the optical horn feature. Each time the control stalk is actuated to a detent position, the opposite headlamp beam from what is currently selected will be energized. Each time the control stalk is actuated to the momentary position with the headlamps turned OFF, the headlamp high beams will be illuminated for as long as the control stalk is held in this position. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic beam select switch status messages to the TIPM over the CAN data bus. The TIPM energizes or de-energizes the selected LOW or HIGH beam circuits. - Turn Signal Control - The control stalk of the multi-function switch is moved upward to activate the RIGHT turn signal circuitry, and, downward to activate the LEFT turn signal circuitry. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, the cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the LEFT turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. When a turn signal is activated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic turn signal switch status messages to the TIPM over the CAN data bus. The TIPM energizes and flashes or de-energizes the selected left or right turn signal circuits. - Washer Control - The control knob on the end of the multi-function switch control stalk is depressed towards the steering column to momentarily activate the washer pump in the WASH mode. The washer pump will continue to operate in the washer mode until the control knob is released. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic washer switch status messages to the TIPM over the CAN data bus. The TIPM responds by energizing or de-energizing the washer pump in the washer mode. - Wiper Control - The control knob on the end of the multi-function switch control stalk is rotated to one of the continuous wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the wiper mode. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic wiper switch status messages to the TIPM over the CAN data bus. The TIPM responds by energizing or de-energizing the wiper motor. The TIPM is programmed to operate the wiper motor at the selected low or high continuous wipe speed, and to provide the selected electronically controlled speed-sensitive intermittent wipe or wipe-after-wash mode features. The multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Description and Operation > Page 16820 Combination Switch: Testing and Inspection MULTI-FUNCTION SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Remove the multi-function switch from the switch mounting housing on the steering column. 2. Disconnect the wire harness connector from the back of the multi-function switch. 3. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the Multi-Function Switch Tests table. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Description and Operation > Page 16821 4. If the switch fails any of the tests, replace the ineffective multi-function switch as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Service and Repair > Removal Combination Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag from the steering wheel. 3. Disconnect the steering wheel wire harness connectors from the upper clockspring connector receptacles. CAUTION: Be certain that the screws that secure the steering wheel puller to the steering wheel are fully engaged in the steering wheel armature without passing through the steering wheel and damaging the clockspring. 4. Remove the steering wheel from the steering column. 5. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 6. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 7. Using hand pressure, press inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 8. Remove the upper shroud from the lower shroud and the steering column. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Service and Repair > Removal > Page 16824 9. Remove the one center screw that secures the lower shroud to the steering column (4). 10. Remove the lower shroud from the steering column. 11. Disconnect the wire harness connector (2) from the back of the multi-function switch housing (1). 12. Remove the two screws (4) that secure the switch to the multi-function switch mounting housing (3). 13. Grasp the switch control stalk and pull it toward the left side of the vehicle to remove the switch from the mounting housing. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Service and Repair > Removal > Page 16825 Combination Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 1. Slide the multi-function switch (1) into the multi-function switch mounting housing (3) from the left side. Be certain that the alignment pins on the top and bottom of the switch are properly engaged in the channels of the mounting housing. 2. Install and tighten the two screws (4) that secure the switch to the mounting housing. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the back of the switch housing. 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Service and Repair > Removal > Page 16826 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). NOTE: When reinstalling the steering wheel, be certain to index the yellow rubber booted engagement dowel on the upper surface of the clockspring rotor between the two fins cast into the lower surface of the steering wheel armature hub. 10. Reinstall the steering wheel onto the steering column. 11. Reconnect the steering wheel wire harness connectors to the upper clockspring connector receptacles. Be certain that the steering wheel wire harness is routed between the steering wheel back trim cover and the steering wheel armature. 12. Reinstall the driver airbag onto the steering wheel. 13. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Cancel Cam > Component Information > Description and Operation > Description Turn Signal Cancel Cam: Description and Operation Description DESCRIPTION The turn signal cancel cam (3) is concealed within the steering column. The turn signal cancel cam consists of two lobes on a molded plastic ring that is snapped into the lower hub of the clockspring rotor. The clockspring mechanism provides turn signal cancellation as well as a constant electrical connection between the horn switch, driver airbag, speed control switches, and remote radio switches on the steering wheel and the instrument panel wire harness on the steering column. The housing of the clockspring (2) is secured to the multi-function switch mounting housing on the steering column and remains stationary. The rotor of the clockspring, including the turn signal cancel cam lobes rotate with the steering wheel. The turn signal cancel cam is serviced as a unit with the clockspring and cannot be repaired. If ineffective or damaged, the entire clockspring unit must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Cancel Cam > Component Information > Description and Operation > Description > Page 16831 Turn Signal Cancel Cam: Description and Operation Operation OPERATION When the multi-function switch control stalk is moved to a latched turn signal position, a turn signal cancel actuator is extended from the inside surface of the switch housing toward the turn signal cancel cam. As the steering wheel is rotated to complete the turn, one of the two cam lobes will contact the actuator, automatically cancelling the turn signal event and releasing the latched multi-function switch control stalk to the neutral (OFF) position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Application and ID Turn Signal Flasher: Application and ID Please Note: The Flasher function for this vehicle is provided by the Body Control Module. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Application and ID > Page 16835 Turn Signal Flasher: Description and Operation Dodge Ram Trucks, 2004-2009 All, do not use a turn signal flasher relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Description and Operation > Description Turn Signal Indicator: Description and Operation Description DESCRIPTION Two turn signal indicators, one right and one left, are standard equipment on all instrument clusters. The turn signal indicators are located near the upper edge of the instrument cluster, the left indicator to the left of the tachometer and the right indicator to the right of the speedometer. Each turn signal indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Turn Warning in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents these indicators from being clearly visible when they are not illuminated. A green Light Emitting Diode (LED) behind each cutout in the opaque layer of the overlay causes each indicator to appear in green through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The turn signal indicators are serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Description and Operation > Description > Page 16840 Turn Signal Indicator: Description and Operation Operation OPERATION The turn signal indicators give an indication to the vehicle operator that the turn signal (left or right indicator flashing) or hazard warning (both left and right indicators flashing) have been selected and are operating. These indicators are controlled by transistors on the instrument cluster electronic circuit board based upon cluster programming, a hard wired multiplex input received by the cluster from the turn signal and hazard warning switch circuitry of the multi-function switch on the turn/hazard switch mux circuit, and electronic messages received from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. Each turn signal indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will allow this indicator to operate whenever the instrument cluster receives a battery current input on the fused B(+) circuit. Therefore, each LED can be illuminated regardless of the ignition switch position. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the turn signal indicators for the following reasons: - Turn Signal-On Input - Each time the cluster detects a turn signal-ON input from the turn signal switch circuitry of the multi-function switch on the turn/hazard switch mux circuit, it sends the appropriate electronic turn signal switch status messages to the TIPM over the CAN data bus. The TIPM responds to these messages by controlling a battery voltage output and the flash rate for either the right or left turn signal lamps. The TIPM also sends the appropriate electronic messages back to the cluster to control the flash rate of the turn signal indicators, as well as to control the click rate of an electromechanical relay soldered onto the cluster electronic circuit board that emulates the sound emitted by a conventional turn signal flasher. The turn signal indicators continue to flash ON and OFF until the cluster receives a turn signal-OFF input from the multi-function switch, or until the ignition switch is turned to the OFF position, whichever occurs first. - Hazard Warning-On Input - Each time the cluster detects a hazard warning-ON input from the hazard warning switch circuitry of the multi-function switch on the turn/hazard switch mux circuit, it sends the appropriate electronic hazard switch status messages to the TIPM over the CAN data bus. The TIPM responds to these messages by controlling a battery voltage output and the flash rate for each of the right and left turn signal lamps. The TIPM also sends the appropriate electronic messages back to the cluster to control the flash rate of the turn signal indicators , as well as to control the click rate of an electromechanical relay soldered onto the cluster electronic circuit board that emulates the sound emitted by a conventional hazard warning flasher. The turn signal indicators continue to flash ON and OFF until the cluster receives a hazard warning-OFF input from the multi-function switch. - Lamp Out Mode - If the TIPM detects an ineffective turn signal lamp or circuit, it increases the flash rate for the remaining operative turn signals and sends an electronic message to the instrument cluster. The instrument cluster then increases the flash rate of the turn signal indicators and the click rate of the electromechanical relay to provide an indication of the problem to the vehicle operator. - Actuator Test - Each time the cluster is put through the actuator test, the turn signal indicators will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of each LED and the cluster control circuitry. The ElectroMechanical Instrument Cluster (EMIC) continually monitors the multi-function switch and electronic messages from the TIPM to determine the proper turn signal and hazard warning indicator operation. For proper diagnosis of the turn signal and hazard warning system, the multi-function switch, the TIPM, the EMIC, the CAN data bus or the electronic communication related to turn signal indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Front Lamp Unit Turn Signal Bulb: Service and Repair Front Lamp Unit Removal BULB - PARK/TURN SIGNAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front lamp unit (1) from the front fender. 3. Firmly grasp the park/turn signal bulb socket (3) on the back of the front lamp unit housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb straight out from the keyed opening in the housing. 5. Pull the base of the bulb (2) straight out of the socket (1). Installation BULB - PARK/TURN SIGNAL CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Front Lamp Unit > Page 16846 1. Align the base of the bulb (2) with the park/turn signal bulb socket (1). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb (3) with the keyed opening on the back of the front lamp unit housing (1). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reinstall the front lamp unit onto the front fender. 7. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Front Lamp Unit > Page 16847 Turn Signal Bulb: Service and Repair Lamp-Tail/Stop/Turn Bulb - Cab And Chassis BULB - CAB AND CHASSIS NOTE: The rear lamp unit contains two bulbs: the park/turn signal/brake/license plate, and the backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Disconnect and isolate the battery negative cable. 2. Remove the four screws (1) that secure the lens (2) to the rear lamp unit housing (5). 3. Push the backup lamp bulb (4), or the park/turn signal/brake/license plate bulb (7) slightly into its socket (3) or (6), then rotate the bulb counterclockwise about 30 degrees to unlock it. 4. Pull the base of the bulb straight out of the socket. Bulb - Pick-Up BULB - PICK-UP NOTE: The rear lamp unit contains two bulbs: park/stop/turn signal/side marker and backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Disconnect and isolate the battery negative cable. 2. Remove the rear lamp unit (1) from the end of the quarter panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Front Lamp Unit > Page 16848 3. Disconnect the wire harness connector (3) from the park/stop/turn signal/side marker (2) or the backup (4) bulb socket on the back of the lamp housing. 4. Firmly grasp the socket on the back of the housing and rotate it counterclockwise about 30 degrees to unlock it. 5. Pull the socket and bulb straight out from the keyed opening in the housing. 6. Pull the base of the bulb straight out of the socket. Bulb - Cab And Chassis BULB - CAB AND CHASSIS CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: The rear lamp unit contains two bulbs: the park/turn signal/brake/license plate, and the backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Align the base of the backup lamp bulb (4), or the park/turn signal/brake/license plate lamp bulb (7) with its socket (3) or (6). 2. Push the bulb straight into the socket until the base is firmly seated, then rotate the bulb clockwise about 30 degrees to lock it into place. 3. Position the lens (2) to the rear lamp unit housing (5). 4. Install and tighten the four screws (1) that secure the lens to the housing. Tighten the screws to 2 Nm (20 in. lbs.). 5. Reconnect the battery negative cable. Bulb - Pick-Up BULB - PICK-UP CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Front Lamp Unit > Page 16849 NOTE: The rear lamp unit contains two bulbs: park/stop/turn signal/side marker and backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Align the base of the bulb with the park/stop/turn signal/side marker (2) or the backup (4) bulb socket. 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of the rear lamp unit housing (1). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reconnect the wire harness connector (3) to the socket. 7. Reinstall the rear lamp unit onto the end of the quarter panel. 8. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Light Bulb > Component Information > Service and Repair > Removal Underhood Light Bulb: Service and Repair Removal BULB 1. Disconnect and isolate the battery negative cable. 2. Insert a small flat bladed tool in the access slot between the underhood lamp housing (1) and the lamp lens (2). 3. Gently pry the lens until it unsnaps from the lamp housing. 4. Depress the bulb holder (2) inward far enough to disengage the terminal loops (3) of the bulb (1) and remove the bulb from the lamp housing (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Light Bulb > Component Information > Service and Repair > Removal > Page 16855 Underhood Light Bulb: Service and Repair Installation BULB CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. 1. Engage one of the terminal loops (3) of the bulb (1) over the bulb holder closest to the connector receptacle of the underhood lamp housing (4). 2. Depress the other bulb holder (2) inward far enough to engage the remaining bulb terminal loop. 3. Position the lens (2) over the lamp housing and use hand pressure to press the lens firmly and evenly onto the housing until it snaps into place. 4. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Locations > Lamp-Vanity-Left Vanity Lamp: Locations Lamp-Vanity-Left Component ID: 187 Component : LAMP-VANITY-LEFT Connector: Name : LAMP-VANITY-LEFT Color : BLACK # of pins : 2 Qualifier : (LIGHT PACKAGE) A READING LAMPS DRIVER M288 20YL/GY B GROUND Z964 20BK Component Location - 53 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Locations > Lamp-Vanity-Left > Page 16860 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Locations > Lamp-Vanity-Left > Page 16861 Vanity Lamp: Locations Lamp-Vanity-Right Component ID: 188 Component : LAMP-VANITY-RIGHT Connector: Name : LAMP-VANITY-RIGHT Color : BLACK # of pins : 2 Qualifier : (LIGHT PACKAGE) A READING LAMPS DRIVER M288 20YL/GY B GROUND Z964 20BK Component Location - 53 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Locations > Lamp-Vanity-Left > Page 16862 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Lamp-Vanity-Left Vanity Lamp: Diagrams Lamp-Vanity-Left Component ID: 187 Component : LAMP-VANITY-LEFT Connector: Name : LAMP-VANITY-LEFT Color : BLACK # of pins : 2 Qualifier : (LIGHT PACKAGE) A READING LAMPS DRIVER M288 20YL/GY B GROUND Z964 20BK Component Location - 53 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Lamp-Vanity-Left > Page 16865 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Lamp-Vanity-Left > Page 16866 Vanity Lamp: Diagrams Lamp-Vanity-Right Component ID: 188 Component : LAMP-VANITY-RIGHT Connector: Name : LAMP-VANITY-RIGHT Color : BLACK # of pins : 2 Qualifier : (LIGHT PACKAGE) A READING LAMPS DRIVER M288 20YL/GY B GROUND Z964 20BK Component Location - 53 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Lamp-Vanity-Left > Page 16867 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Service and Repair > Removal - Bulb Vanity Lamp: Service and Repair Removal - Bulb REMOVAL - BULB NOTE: Vehicles equipped with optional vanity lamps have a mirror with a single lamp that is integral to each sun visor. Each lamp is independently controlled by an integral switch that is automatically actuated by the mirror cover. The bulb types and service procedures are identical for each of these lamps. 1. Disconnect and isolate the battery negative cable. 2. Insert a small flat-bladed screwdriver on either side near the top or the bottom between the vanity lamp lens (2) and the lamp housing of the sun visor (1). 3. Carefully pry the lens outward until it unsnaps from the lamp housing. 4. Using small needle-nose pliers, carefully grasp the bulb (2) and pull the base out of the lamp socket. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Service and Repair > Removal - Bulb > Page 16870 Vanity Lamp: Service and Repair Installation - Bulb INSTALLATION - BULB CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: Vehicles equipped with optional vanity lamps have a mirror with a single lamp that is integral to each sun visor. Each lamp is independently controlled by an integral switch that is automatically actuated by the mirror cover. The bulb types and service procedures are identical for each of these lamps. 1. Using small needle-nose pliers, carefully grasp the vanity lamp bulb (2) and align the base of the bulb with the socket in the lamp housing of the sun visor (1). 2. Push the bulb straight into the socket until the base is fully seated. 3. Insert one tab on the top or the bottom of the lens (2) into the appropriate slot at the top or bottom of the lamp housing. 4. Flex the lens far enough to engage the loose tab into its slot in the lamp housing. 5. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 16876 Heated Glass Element Relay: Description and Operation Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Description and Operation > Description Heated Glass Element Switch: Description and Operation Description DESCRIPTION The switch for the rear window defogger (EBL) system (1) is integrated into the A/C-heater control (2), which is located in the center of the instrument panel. When the rear window defogger switch is pressed to ON, a request signal is sent on the CAN-B Bus to the totally integrated power module (TIPM) to operate the EBL system. When the high side driver in the totally integrated power module (TIPM) is energized, current is directed to the rear defogger grid lines and to the heated side view mirrors. The grid lines heat the glass to help clear the surface of fog or frost. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Description and Operation > Description > Page 16881 Heated Glass Element Switch: Description and Operation Operation OPERATION An amber indicator will illuminate when the rear window defogger switch is activated. When activated, the switch sends a request signal to the to the totally integrated power module (TIPM) to energize the internal EBL high side driver to provide battery current to the rear window defogger grid lines and to the heated side view mirrors. NOTE: The EBL system turns off automatically after 15 minutes of initial operation. Each following activation cycle of the EBL system will last 10 minutes. The EBL system will be automatically turned off after an initial programmed time interval of about 15 minutes, as long as the ignition switch is in RUN. After the initial time interval has expired, if the rear window defogger switch is pressed to ON again during the same ignition cycle, the EBL system will automatically turn off after about 10 minutes. The EBL system will automatically shut off if the ignition switch is turned to any position other than RUN, or it can be turned off manually by pressing the rear window defogger switch a second time. The rear window defogger switch is diagnosed using a scan tool. The rear window defogger switch and the rear window defogger indicator cannot be repaired and the A/C-heater control must be replaced if found inoperative or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Rear Defogger > Rear Defogger Relay > Component Information > Locations Rear Defogger Relay: Locations Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Rear Defogger > Rear Defogger Relay > Component Information > Locations > Page 16886 Rear Defogger Relay: Description and Operation Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 16891 Heated Glass Element Relay: Description and Operation Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations Rear Defogger Relay: Locations Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations > Page 16895 Rear Defogger Relay: Description and Operation Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Description Heated Glass Element Switch: Description and Operation Description DESCRIPTION The switch for the rear window defogger (EBL) system (1) is integrated into the A/C-heater control (2), which is located in the center of the instrument panel. When the rear window defogger switch is pressed to ON, a request signal is sent on the CAN-B Bus to the totally integrated power module (TIPM) to operate the EBL system. When the high side driver in the totally integrated power module (TIPM) is energized, current is directed to the rear defogger grid lines and to the heated side view mirrors. The grid lines heat the glass to help clear the surface of fog or frost. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Description > Page 16901 Heated Glass Element Switch: Description and Operation Operation OPERATION An amber indicator will illuminate when the rear window defogger switch is activated. When activated, the switch sends a request signal to the to the totally integrated power module (TIPM) to energize the internal EBL high side driver to provide battery current to the rear window defogger grid lines and to the heated side view mirrors. NOTE: The EBL system turns off automatically after 15 minutes of initial operation. Each following activation cycle of the EBL system will last 10 minutes. The EBL system will be automatically turned off after an initial programmed time interval of about 15 minutes, as long as the ignition switch is in RUN. After the initial time interval has expired, if the rear window defogger switch is pressed to ON again during the same ignition cycle, the EBL system will automatically turn off after about 10 minutes. The EBL system will automatically shut off if the ignition switch is turned to any position other than RUN, or it can be turned off manually by pressing the rear window defogger switch a second time. The rear window defogger switch is diagnosed using a scan tool. The rear window defogger switch and the rear window defogger indicator cannot be repaired and the A/C-heater control must be replaced if found inoperative or damaged. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite Power Window Switch: Locations Switch-Power Sliding Backlite Component ID: 476 Component : SWITCH-POWER SLIDING BACKLITE Connector: Name : SWITCH-POWER SLIDING BACKLITE Color : BLACK # of pins : 8 Qualifier : (QUAD CAB/EXCEPT BASE) Pin Description Circuit 1-2 GROUND Z794 12BK 3 GROUND Z975 12BK 4 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 12PK/YL 5 POWER BACKLITE OPEN (+) Q950 12OR/LG 6 PANEL LAMPS DRIVER P301 20LG/OR 7 GROUND Z976 20BK 8 POWER BACKLITE OPEN (-) Q951 12OR/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 16906 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 16907 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 16908 Power Window Switch: Locations Switch-Power Window-Left Rear Component ID: 477 Component : SWITCH-POWER WINDOW-LEFT REAR Connector: Name : SWITCH-POWER WINDOW-LEFT REAR Color : BLUE # of pins : 6 Pin Description Circuit 1 DRIVER REAR WINDOW DRIVER (UP) Q111 14TN/YL Pin Description Circuit 1 DRIVER REAR WINDOW DRIVER (DOWN) Q211 14TN/LB 2 LEFT REAR WINDOW DRIVER (DOWN) Q611 14OR/GY 3-4 LEFT REAR WINDOW DRIVER (UP) Q411 14OR/WT 5 DRIVER REAR WINDOW DRIVER (DOWN) Q211 14TN/LB 5 DRIVER REAR WINDOW DRIVER (UP) Q111 14TN/YL 6 POWER WINDOW SWITCH FEED Q15 14OR/LB Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 16909 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 16910 Power Window Switch: Locations Switch-Power Window-Passenger Component ID: 478 Component : SWITCH-POWER WINDOW-PASSENGER Connector: Name : SWITCH-POWER WINDOW-PASSENGER Color : BLUE # of pins : 6 Pin Description Circuit 1 RIGHT FRONT WINDOW DRIVER (UP) Q12 12OR/BR 2 MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Q26 12OR/GY 3-4 MASTER WINDOW SWITCH RIGHT FRONT (UP) Q16 12OR/TN 5 RIGHT FRONT WINDOW DRIVER (DOWN) Q22 12OR/VT 6 POWER WINDOW SWITCH FEED Q15 12OR/LB Component Location - 56 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 16911 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 16912 Power Window Switch: Locations Switch-Power Window-Right Rear Component ID: 479 Component : SWITCH-POWER WINDOW-RIGHT REAR Connector: Name : SWITCH-POWER WINDOW-RIGHT REAR Color : BLUE # of pins : 6 Pin Description Circuit 1 PASSENGER REAR WINDOW DRIVER (UP) Q112 14TN/YL Pin Description Circuit 1 PASSENGER REAR WINDOW DRIVER (DOWN) Q212 14TN/LB 2 RIGHT REAR WINDOW DRIVER (DOWN) Q612 14OR/GY 3-4 RIGHT REAR WINDOW DRIVER (UP) Q412 14OR/WT 5 PASSENGER REAR WINDOW DRIVER (DOWN) Q212 14TN/LB 5 PASSENGER REAR WINDOW DRIVER (UP) Q112 14TN/YL 6 POWER WINDOW SWITCH FEED Q15 14TN/LG Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 16913 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 16914 Power Window Switch: Locations Switch-Window/Door Lock-Driver Component ID: 494 Component : SWITCH-WINDOW/DOOR LOCK-DRIVER Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C1 Color : BLUE # of pins : 12 Pin Description Circuit 1 RIGHT REAR WINDOW DRIVER (DOWN) Q612 14OR/DB 2 RIGHT REAR WINDOW DRIVER (UP) Q412 14OR/LB 3 MASTER WINDOW SWITCH RIGHT FRONT (UP) Q16 12OR/TN 4 LEFT REAR WINDOW DRIVER (UP) Q411 14OR/WT 5 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 6 MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Q26 12OR/GY 7 DRIVER DOOR LOCK SWITCH MUX G161 20VT/DG 8 GROUND Z939 12BK 9 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 12PK/YL 10 LEFT REAR WINDOW DRIVER (DOWN) Q611 14OR/GY 11 GROUND Z939 18BK 12 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 16915 Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C2 Color : BLUE # of pins : 8 Pin Description Circuit 1 LEFT MIRROR UP DRIVER P71 20TN/DG 2 LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) P195 18LG/YL 3 FUSED B(+) A940 18RD 4 RIGHT MIRROR LEFT DRIVER P74 18TN/OR 5 GROUND Z939 18BK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 16916 6 LEFT MIRROR LEFT DRIVER P75 20TN/LG 7 RIGHT MIRROR UP DRIVER P72 18TN/GY 8 POWER WINDOW SWITCH FEED Q15 12OR/LB Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite Power Window Switch: Diagrams Switch-Power Sliding Backlite Component ID: 476 Component : SWITCH-POWER SLIDING BACKLITE Connector: Name : SWITCH-POWER SLIDING BACKLITE Color : BLACK # of pins : 8 Qualifier : (QUAD CAB/EXCEPT BASE) Pin Description Circuit 1-2 GROUND Z794 12BK 3 GROUND Z975 12BK 4 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 12PK/YL 5 POWER BACKLITE OPEN (+) Q950 12OR/LG 6 PANEL LAMPS DRIVER P301 20LG/OR 7 GROUND Z976 20BK 8 POWER BACKLITE OPEN (-) Q951 12OR/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 16919 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 16920 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 16921 Power Window Switch: Diagrams Switch-Power Window-Left Rear Component ID: 477 Component : SWITCH-POWER WINDOW-LEFT REAR Connector: Name : SWITCH-POWER WINDOW-LEFT REAR Color : BLUE # of pins : 6 Pin Description Circuit 1 DRIVER REAR WINDOW DRIVER (UP) Q111 14TN/YL Pin Description Circuit 1 DRIVER REAR WINDOW DRIVER (DOWN) Q211 14TN/LB 2 LEFT REAR WINDOW DRIVER (DOWN) Q611 14OR/GY 3-4 LEFT REAR WINDOW DRIVER (UP) Q411 14OR/WT 5 DRIVER REAR WINDOW DRIVER (DOWN) Q211 14TN/LB 5 DRIVER REAR WINDOW DRIVER (UP) Q111 14TN/YL 6 POWER WINDOW SWITCH FEED Q15 14OR/LB Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 16922 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 16923 Power Window Switch: Diagrams Switch-Power Window-Passenger Component ID: 478 Component : SWITCH-POWER WINDOW-PASSENGER Connector: Name : SWITCH-POWER WINDOW-PASSENGER Color : BLUE # of pins : 6 Pin Description Circuit 1 RIGHT FRONT WINDOW DRIVER (UP) Q12 12OR/BR 2 MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Q26 12OR/GY 3-4 MASTER WINDOW SWITCH RIGHT FRONT (UP) Q16 12OR/TN 5 RIGHT FRONT WINDOW DRIVER (DOWN) Q22 12OR/VT 6 POWER WINDOW SWITCH FEED Q15 12OR/LB Component Location - 56 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 16924 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 16925 Power Window Switch: Diagrams Switch-Power Window-Right Rear Component ID: 479 Component : SWITCH-POWER WINDOW-RIGHT REAR Connector: Name : SWITCH-POWER WINDOW-RIGHT REAR Color : BLUE # of pins : 6 Pin Description Circuit 1 PASSENGER REAR WINDOW DRIVER (UP) Q112 14TN/YL Pin Description Circuit 1 PASSENGER REAR WINDOW DRIVER (DOWN) Q212 14TN/LB 2 RIGHT REAR WINDOW DRIVER (DOWN) Q612 14OR/GY 3-4 RIGHT REAR WINDOW DRIVER (UP) Q412 14OR/WT 5 PASSENGER REAR WINDOW DRIVER (DOWN) Q212 14TN/LB 5 PASSENGER REAR WINDOW DRIVER (UP) Q112 14TN/YL 6 POWER WINDOW SWITCH FEED Q15 14TN/LG Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 16926 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 16927 Power Window Switch: Diagrams Switch-Window/Door Lock-Driver Component ID: 494 Component : SWITCH-WINDOW/DOOR LOCK-DRIVER Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C1 Color : BLUE # of pins : 12 Pin Description Circuit 1 RIGHT REAR WINDOW DRIVER (DOWN) Q612 14OR/DB 2 RIGHT REAR WINDOW DRIVER (UP) Q412 14OR/LB 3 MASTER WINDOW SWITCH RIGHT FRONT (UP) Q16 12OR/TN 4 LEFT REAR WINDOW DRIVER (UP) Q411 14OR/WT 5 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 6 MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Q26 12OR/GY 7 DRIVER DOOR LOCK SWITCH MUX G161 20VT/DG 8 GROUND Z939 12BK 9 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 12PK/YL 10 LEFT REAR WINDOW DRIVER (DOWN) Q611 14OR/GY 11 GROUND Z939 18BK 12 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 16928 Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C2 Color : BLUE # of pins : 8 Pin Description Circuit 1 LEFT MIRROR UP DRIVER P71 20TN/DG 2 LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) P195 18LG/YL 3 FUSED B(+) A940 18RD 4 RIGHT MIRROR LEFT DRIVER P74 18TN/OR 5 GROUND Z939 18BK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 16929 6 LEFT MIRROR LEFT DRIVER P75 20TN/LG 7 RIGHT MIRROR UP DRIVER P72 18TN/GY 8 POWER WINDOW SWITCH FEED Q15 12OR/LB Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Description Power Window Switch: Description and Operation Description DESCRIPTION A window/lock switch is used on all models equipped with power locks, power windows, and power mirrors. The window/lock switch houses the following switches: - Power Lock Switch - A two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Mirror Selector Switch - A three-position rocker switch selects the right or left power mirror for adjustment, or turns the power mirror system Off. - Power Mirror Adjustment Switches - Four momentary, arrowhead shaped, directional switches allow the driver to adjust the selected power mirror in the Up, Down, Right, or Left directions. - Power Window Lockout Switch - A two-way, latching, push-button switch allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches. - Power Window Switches - A two-way, momentary power window switch for the driver side front door. This switch also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, there are individual master switches for each passenger door power window. The window/lock switch also incorporates several green Light-Emitting Diodes (LEDs) that illuminate the power lock and power window switch paddles, and the power mirror switch directional buttons to improve switch visibility. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Description > Page 16932 Power Window Switch: Description and Operation Operation OPERATION The window/lock switch combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single unit. Power Lock Switch The power lock switch circuitry is connected in series between ground and the driver door switch mux input of the instrument cluster. Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the instrument cluster input, which allows the instrument cluster to sense the switch position. Based upon the power lock switch input, the instrument cluster controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door latches. The Light-Emitting Diode (LED) in the power lock switch is connected to battery current through the power window circuit breaker in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run-acc) circuit. The switch will be illuminated whenever the ignition switch is in the On or Accessory positions. Power Window Switches The power window switch circuitry is connected to battery current through a circuit breaker in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run-acc) circuit so that the power windows will operate whenever the ignition switch is in the On or Accessory positions. Each two-way, momentary master passenger power window switch provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The switch for the driver side front door power window is labeled "Auto" and includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the master switches. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Power Mirror Switches The power mirror switch circuitry is connected to battery current through a fuse in the TIPM on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one to select the left mirror, and a neutral Off position. After the right or left mirror is selected, one of four directional buttons is depressed to move the selected mirror Up, Down, Right or Left. The power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the power mirror switch is connected to battery current through the power window circuit breaker in the TIPM on a fused ignition switch output (run-acc) circuit so that the switch directional buttons will be illuminated whenever the ignition switch is in the On or Accessory positions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Window/Lock Switch Power Window Switch: Testing and Inspection Window/Lock Switch WINDOW/LOCK SWITCH The Light-Emitting Diode (LED) illumination lamps for all of the Driver Door Module (DDM) power window, power lock, and power mirror switches receive battery current through the power window circuit breaker in the Totally Integrated Power Module (TIPM). If all of the LED's are inoperative in the DDM, be certain to diagnose the power window system before replacing the switch unit. If only one LED in the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty DDM. Refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles. 2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position. If not OK, replace the faulty DDM as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Window/Lock Switch > Page 16935 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Window/Lock Switch > Page 16936 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Window/Lock Switch > Page 16937 Power Window Switch: Testing and Inspection Window Switch WINDOW SWITCH The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in both the power window and lock switch units and the power windows are inoperative. If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch units with the inoperative LED(s) is faulty and must be replaced. For complete circuit diagrams, refer to the appropriate wiring information. 1. Check the fuse in the Totally Integrated Power Module (TIPM) and the circuit breaker located near the park brake pedal. If OK, go to STEP 2. If not OK, replace the faulty fuse or circuit breaker. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the Totally Integrated Power Module (TIPM). If OK, turn the ignition switch to the Off position and go to STEP 3. If not OK, check circuit breaker and repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch unit from the door trim panel (passenger doors). The drivers door switch is included with the window/lock switch. Unplug the wire harness connector from the switch unit. 4. Test the power window switch continuity. See the Power Window Switch Continuity charts to determine if the continuity is correct in the Off, Up and Down switch positions . If OK, Refer to POWER WINDOWS TESTING. If not OK, replace the faulty switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Removal Power Window Switch: Service and Repair Removal REMOVAL FRONT PASSENGER 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel 3. Remove the switch from the trim panel bezel. REAR PASSENGER 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Gently pry switch from door trim panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Removal > Page 16940 Power Window Switch: Service and Repair Installation INSTALLATION FRONT PASSENGER 1. Insert switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. REAR PASSENGER 1. Install switch to door trim panel 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Motor-Power Sliding Backlite Power Window Motor: Locations Motor-Power Sliding Backlite Component ID: 220 Component : MOTOR-POWER SLIDING BACKLITE Connector: Name : MOTOR-POWER SLIDING BACKLITE Color : # of pins : 2 Qualifier : (QUAD CAB/EXCEPT BASE) Pin Description Circuit 1 POWER BACKLITE OPEN (+) Q950 12OR/LG 2 POWER BACKLITE OPEN (-) Q951 12OR/VT Component Location - 64 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Motor-Power Sliding Backlite > Page 16946 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Motor-Power Sliding Backlite > Page 16947 Power Window Motor: Locations Motor-Window-Driver Component ID: 227 Component : MOTOR-WINDOW-DRIVER Connector: Name : MOTOR-WINDOW-DRIVER Color : BLACK # of pins : 2 A DRIVER WINDOW DRIVER DOWN Q21 14OR/WT B DRIVER WINDOW DRIVER UP Q11 14OR/LG Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Motor-Power Sliding Backlite > Page 16948 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Motor-Power Sliding Backlite > Page 16949 Power Window Motor: Locations Motor-Window-Left Rear Component ID: 228 Component : MOTOR-WINDOW-LEFT REAR Connector: Name : MOTOR-WINDOW-LEFT REAR Color : BLACK # of pins : 2 A DRIVER REAR WINDOW DRIVER (DOWN) Q211 14TN/LB B DRIVER REAR WINDOW DRIVER (UP) Q111 14TN/YL Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Motor-Power Sliding Backlite > Page 16950 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Motor-Power Sliding Backlite > Page 16951 Power Window Motor: Locations Motor-Window-Passenger Component ID: 229 Component : MOTOR-WINDOW-PASSENGER Connector: Name : MOTOR-WINDOW-PASSENGER Color : BLACK # of pins : 2 A PASSENGER WINDOW DRIVER DOWN Q22 12OR/VT B PASSENGER WINDOW DRIVER UP Q12 12OR/BR Component Location - 56 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Motor-Power Sliding Backlite > Page 16952 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Motor-Power Sliding Backlite > Page 16953 Power Window Motor: Locations Motor-Window-Right Rear Component ID: 230 Component : MOTOR-WINDOW-RIGHT REAR Connector: Name : MOTOR-WINDOW-RIGHT REAR Color : BLACK # of pins : 2 A PASSENGER REAR WINDOW DRIVER (DOWN) Q212 14TN/LB B PASSENGER REAR WINDOW DRIVER (UP) Q112 14TN/YL Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Motor-Power Sliding Backlite > Page 16954 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Motor-Power Sliding Backlite Power Window Motor: Diagrams Motor-Power Sliding Backlite Component ID: 220 Component : MOTOR-POWER SLIDING BACKLITE Connector: Name : MOTOR-POWER SLIDING BACKLITE Color : # of pins : 2 Qualifier : (QUAD CAB/EXCEPT BASE) Pin Description Circuit 1 POWER BACKLITE OPEN (+) Q950 12OR/LG 2 POWER BACKLITE OPEN (-) Q951 12OR/VT Component Location - 64 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Motor-Power Sliding Backlite > Page 16957 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Motor-Power Sliding Backlite > Page 16958 Power Window Motor: Diagrams Motor-Window-Driver Component ID: 227 Component : MOTOR-WINDOW-DRIVER Connector: Name : MOTOR-WINDOW-DRIVER Color : BLACK # of pins : 2 A DRIVER WINDOW DRIVER DOWN Q21 14OR/WT B DRIVER WINDOW DRIVER UP Q11 14OR/LG Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Motor-Power Sliding Backlite > Page 16959 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Motor-Power Sliding Backlite > Page 16960 Power Window Motor: Diagrams Motor-Window-Left Rear Component ID: 228 Component : MOTOR-WINDOW-LEFT REAR Connector: Name : MOTOR-WINDOW-LEFT REAR Color : BLACK # of pins : 2 A DRIVER REAR WINDOW DRIVER (DOWN) Q211 14TN/LB B DRIVER REAR WINDOW DRIVER (UP) Q111 14TN/YL Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Motor-Power Sliding Backlite > Page 16961 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Motor-Power Sliding Backlite > Page 16962 Power Window Motor: Diagrams Motor-Window-Passenger Component ID: 229 Component : MOTOR-WINDOW-PASSENGER Connector: Name : MOTOR-WINDOW-PASSENGER Color : BLACK # of pins : 2 A PASSENGER WINDOW DRIVER DOWN Q22 12OR/VT B PASSENGER WINDOW DRIVER UP Q12 12OR/BR Component Location - 56 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Motor-Power Sliding Backlite > Page 16963 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Motor-Power Sliding Backlite > Page 16964 Power Window Motor: Diagrams Motor-Window-Right Rear Component ID: 230 Component : MOTOR-WINDOW-RIGHT REAR Connector: Name : MOTOR-WINDOW-RIGHT REAR Color : BLACK # of pins : 2 A PASSENGER REAR WINDOW DRIVER (DOWN) Q212 14TN/LB B PASSENGER REAR WINDOW DRIVER (UP) Q112 14TN/YL Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Motor-Power Sliding Backlite > Page 16965 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Removal Power Window Motor: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the rear seats. 3. Remove the rear cab back panel. 4. Remove the 2 mounting bolts (1). 5. Disconnect the electrical connector to the power motor. 6. Rotate the assembly and remove the 3 screws (1) that attach the motor to the regulator. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Removal > Page 16968 Power Window Motor: Service and Repair Installation INSTALLATION 1. Install the power motor to the regulator with the 3 screws (1). 2. Connect the electrical connector to the power motor. 3. Install the 2 mounting bolts (1). 4. Install the rear cab back panel. 5. Install the rear seats. 6. Connect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite Power Window Switch: Locations Switch-Power Sliding Backlite Component ID: 476 Component : SWITCH-POWER SLIDING BACKLITE Connector: Name : SWITCH-POWER SLIDING BACKLITE Color : BLACK # of pins : 8 Qualifier : (QUAD CAB/EXCEPT BASE) Pin Description Circuit 1-2 GROUND Z794 12BK 3 GROUND Z975 12BK 4 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 12PK/YL 5 POWER BACKLITE OPEN (+) Q950 12OR/LG 6 PANEL LAMPS DRIVER P301 20LG/OR 7 GROUND Z976 20BK 8 POWER BACKLITE OPEN (-) Q951 12OR/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 16973 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 16974 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 16975 Power Window Switch: Locations Switch-Power Window-Left Rear Component ID: 477 Component : SWITCH-POWER WINDOW-LEFT REAR Connector: Name : SWITCH-POWER WINDOW-LEFT REAR Color : BLUE # of pins : 6 Pin Description Circuit 1 DRIVER REAR WINDOW DRIVER (UP) Q111 14TN/YL Pin Description Circuit 1 DRIVER REAR WINDOW DRIVER (DOWN) Q211 14TN/LB 2 LEFT REAR WINDOW DRIVER (DOWN) Q611 14OR/GY 3-4 LEFT REAR WINDOW DRIVER (UP) Q411 14OR/WT 5 DRIVER REAR WINDOW DRIVER (DOWN) Q211 14TN/LB 5 DRIVER REAR WINDOW DRIVER (UP) Q111 14TN/YL 6 POWER WINDOW SWITCH FEED Q15 14OR/LB Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 16976 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 16977 Power Window Switch: Locations Switch-Power Window-Passenger Component ID: 478 Component : SWITCH-POWER WINDOW-PASSENGER Connector: Name : SWITCH-POWER WINDOW-PASSENGER Color : BLUE # of pins : 6 Pin Description Circuit 1 RIGHT FRONT WINDOW DRIVER (UP) Q12 12OR/BR 2 MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Q26 12OR/GY 3-4 MASTER WINDOW SWITCH RIGHT FRONT (UP) Q16 12OR/TN 5 RIGHT FRONT WINDOW DRIVER (DOWN) Q22 12OR/VT 6 POWER WINDOW SWITCH FEED Q15 12OR/LB Component Location - 56 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 16978 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 16979 Power Window Switch: Locations Switch-Power Window-Right Rear Component ID: 479 Component : SWITCH-POWER WINDOW-RIGHT REAR Connector: Name : SWITCH-POWER WINDOW-RIGHT REAR Color : BLUE # of pins : 6 Pin Description Circuit 1 PASSENGER REAR WINDOW DRIVER (UP) Q112 14TN/YL Pin Description Circuit 1 PASSENGER REAR WINDOW DRIVER (DOWN) Q212 14TN/LB 2 RIGHT REAR WINDOW DRIVER (DOWN) Q612 14OR/GY 3-4 RIGHT REAR WINDOW DRIVER (UP) Q412 14OR/WT 5 PASSENGER REAR WINDOW DRIVER (DOWN) Q212 14TN/LB 5 PASSENGER REAR WINDOW DRIVER (UP) Q112 14TN/YL 6 POWER WINDOW SWITCH FEED Q15 14TN/LG Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 16980 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 16981 Power Window Switch: Locations Switch-Window/Door Lock-Driver Component ID: 494 Component : SWITCH-WINDOW/DOOR LOCK-DRIVER Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C1 Color : BLUE # of pins : 12 Pin Description Circuit 1 RIGHT REAR WINDOW DRIVER (DOWN) Q612 14OR/DB 2 RIGHT REAR WINDOW DRIVER (UP) Q412 14OR/LB 3 MASTER WINDOW SWITCH RIGHT FRONT (UP) Q16 12OR/TN 4 LEFT REAR WINDOW DRIVER (UP) Q411 14OR/WT 5 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 6 MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Q26 12OR/GY 7 DRIVER DOOR LOCK SWITCH MUX G161 20VT/DG 8 GROUND Z939 12BK 9 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 12PK/YL 10 LEFT REAR WINDOW DRIVER (DOWN) Q611 14OR/GY 11 GROUND Z939 18BK 12 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 16982 Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C2 Color : BLUE # of pins : 8 Pin Description Circuit 1 LEFT MIRROR UP DRIVER P71 20TN/DG 2 LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) P195 18LG/YL 3 FUSED B(+) A940 18RD 4 RIGHT MIRROR LEFT DRIVER P74 18TN/OR 5 GROUND Z939 18BK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 16983 6 LEFT MIRROR LEFT DRIVER P75 20TN/LG 7 RIGHT MIRROR UP DRIVER P72 18TN/GY 8 POWER WINDOW SWITCH FEED Q15 12OR/LB Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite Power Window Switch: Diagrams Switch-Power Sliding Backlite Component ID: 476 Component : SWITCH-POWER SLIDING BACKLITE Connector: Name : SWITCH-POWER SLIDING BACKLITE Color : BLACK # of pins : 8 Qualifier : (QUAD CAB/EXCEPT BASE) Pin Description Circuit 1-2 GROUND Z794 12BK 3 GROUND Z975 12BK 4 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 12PK/YL 5 POWER BACKLITE OPEN (+) Q950 12OR/LG 6 PANEL LAMPS DRIVER P301 20LG/OR 7 GROUND Z976 20BK 8 POWER BACKLITE OPEN (-) Q951 12OR/VT Component Location - 47 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 16986 Component Location - 45 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 16987 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 16988 Power Window Switch: Diagrams Switch-Power Window-Left Rear Component ID: 477 Component : SWITCH-POWER WINDOW-LEFT REAR Connector: Name : SWITCH-POWER WINDOW-LEFT REAR Color : BLUE # of pins : 6 Pin Description Circuit 1 DRIVER REAR WINDOW DRIVER (UP) Q111 14TN/YL Pin Description Circuit 1 DRIVER REAR WINDOW DRIVER (DOWN) Q211 14TN/LB 2 LEFT REAR WINDOW DRIVER (DOWN) Q611 14OR/GY 3-4 LEFT REAR WINDOW DRIVER (UP) Q411 14OR/WT 5 DRIVER REAR WINDOW DRIVER (DOWN) Q211 14TN/LB 5 DRIVER REAR WINDOW DRIVER (UP) Q111 14TN/YL 6 POWER WINDOW SWITCH FEED Q15 14OR/LB Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 16989 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 16990 Power Window Switch: Diagrams Switch-Power Window-Passenger Component ID: 478 Component : SWITCH-POWER WINDOW-PASSENGER Connector: Name : SWITCH-POWER WINDOW-PASSENGER Color : BLUE # of pins : 6 Pin Description Circuit 1 RIGHT FRONT WINDOW DRIVER (UP) Q12 12OR/BR 2 MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Q26 12OR/GY 3-4 MASTER WINDOW SWITCH RIGHT FRONT (UP) Q16 12OR/TN 5 RIGHT FRONT WINDOW DRIVER (DOWN) Q22 12OR/VT 6 POWER WINDOW SWITCH FEED Q15 12OR/LB Component Location - 56 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 16991 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 16992 Power Window Switch: Diagrams Switch-Power Window-Right Rear Component ID: 479 Component : SWITCH-POWER WINDOW-RIGHT REAR Connector: Name : SWITCH-POWER WINDOW-RIGHT REAR Color : BLUE # of pins : 6 Pin Description Circuit 1 PASSENGER REAR WINDOW DRIVER (UP) Q112 14TN/YL Pin Description Circuit 1 PASSENGER REAR WINDOW DRIVER (DOWN) Q212 14TN/LB 2 RIGHT REAR WINDOW DRIVER (DOWN) Q612 14OR/GY 3-4 RIGHT REAR WINDOW DRIVER (UP) Q412 14OR/WT 5 PASSENGER REAR WINDOW DRIVER (DOWN) Q212 14TN/LB 5 PASSENGER REAR WINDOW DRIVER (UP) Q112 14TN/YL 6 POWER WINDOW SWITCH FEED Q15 14TN/LG Component Location - 57 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 16993 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 16994 Power Window Switch: Diagrams Switch-Window/Door Lock-Driver Component ID: 494 Component : SWITCH-WINDOW/DOOR LOCK-DRIVER Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C1 Color : BLUE # of pins : 12 Pin Description Circuit 1 RIGHT REAR WINDOW DRIVER (DOWN) Q612 14OR/DB 2 RIGHT REAR WINDOW DRIVER (UP) Q412 14OR/LB 3 MASTER WINDOW SWITCH RIGHT FRONT (UP) Q16 12OR/TN 4 LEFT REAR WINDOW DRIVER (UP) Q411 14OR/WT 5 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG 6 MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Q26 12OR/GY 7 DRIVER DOOR LOCK SWITCH MUX G161 20VT/DG 8 GROUND Z939 12BK 9 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 12PK/YL 10 LEFT REAR WINDOW DRIVER (DOWN) Q611 14OR/GY 11 GROUND Z939 18BK 12 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 16995 Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C2 Color : BLUE # of pins : 8 Pin Description Circuit 1 LEFT MIRROR UP DRIVER P71 20TN/DG 2 LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) P195 18LG/YL 3 FUSED B(+) A940 18RD 4 RIGHT MIRROR LEFT DRIVER P74 18TN/OR 5 GROUND Z939 18BK Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 16996 6 LEFT MIRROR LEFT DRIVER P75 20TN/LG 7 RIGHT MIRROR UP DRIVER P72 18TN/GY 8 POWER WINDOW SWITCH FEED Q15 12OR/LB Component Location - 55 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Description and Operation > Description Power Window Switch: Description and Operation Description DESCRIPTION A window/lock switch is used on all models equipped with power locks, power windows, and power mirrors. The window/lock switch houses the following switches: - Power Lock Switch - A two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Mirror Selector Switch - A three-position rocker switch selects the right or left power mirror for adjustment, or turns the power mirror system Off. - Power Mirror Adjustment Switches - Four momentary, arrowhead shaped, directional switches allow the driver to adjust the selected power mirror in the Up, Down, Right, or Left directions. - Power Window Lockout Switch - A two-way, latching, push-button switch allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches. - Power Window Switches - A two-way, momentary power window switch for the driver side front door. This switch also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, there are individual master switches for each passenger door power window. The window/lock switch also incorporates several green Light-Emitting Diodes (LEDs) that illuminate the power lock and power window switch paddles, and the power mirror switch directional buttons to improve switch visibility. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Description and Operation > Description > Page 16999 Power Window Switch: Description and Operation Operation OPERATION The window/lock switch combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single unit. Power Lock Switch The power lock switch circuitry is connected in series between ground and the driver door switch mux input of the instrument cluster. Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the instrument cluster input, which allows the instrument cluster to sense the switch position. Based upon the power lock switch input, the instrument cluster controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door latches. The Light-Emitting Diode (LED) in the power lock switch is connected to battery current through the power window circuit breaker in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run-acc) circuit. The switch will be illuminated whenever the ignition switch is in the On or Accessory positions. Power Window Switches The power window switch circuitry is connected to battery current through a circuit breaker in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run-acc) circuit so that the power windows will operate whenever the ignition switch is in the On or Accessory positions. Each two-way, momentary master passenger power window switch provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The switch for the driver side front door power window is labeled "Auto" and includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the master switches. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Power Mirror Switches The power mirror switch circuitry is connected to battery current through a fuse in the TIPM on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one to select the left mirror, and a neutral Off position. After the right or left mirror is selected, one of four directional buttons is depressed to move the selected mirror Up, Down, Right or Left. The power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the power mirror switch is connected to battery current through the power window circuit breaker in the TIPM on a fused ignition switch output (run-acc) circuit so that the switch directional buttons will be illuminated whenever the ignition switch is in the On or Accessory positions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Window/Lock Switch Power Window Switch: Testing and Inspection Window/Lock Switch WINDOW/LOCK SWITCH The Light-Emitting Diode (LED) illumination lamps for all of the Driver Door Module (DDM) power window, power lock, and power mirror switches receive battery current through the power window circuit breaker in the Totally Integrated Power Module (TIPM). If all of the LED's are inoperative in the DDM, be certain to diagnose the power window system before replacing the switch unit. If only one LED in the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty DDM. Refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles. 2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position. If not OK, replace the faulty DDM as required. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Window/Lock Switch > Page 17002 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Window/Lock Switch > Page 17003 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Window/Lock Switch > Page 17004 Power Window Switch: Testing and Inspection Window Switch WINDOW SWITCH The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in both the power window and lock switch units and the power windows are inoperative. If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch units with the inoperative LED(s) is faulty and must be replaced. For complete circuit diagrams, refer to the appropriate wiring information. 1. Check the fuse in the Totally Integrated Power Module (TIPM) and the circuit breaker located near the park brake pedal. If OK, go to STEP 2. If not OK, replace the faulty fuse or circuit breaker. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the Totally Integrated Power Module (TIPM). If OK, turn the ignition switch to the Off position and go to STEP 3. If not OK, check circuit breaker and repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch unit from the door trim panel (passenger doors). The drivers door switch is included with the window/lock switch. Unplug the wire harness connector from the switch unit. 4. Test the power window switch continuity. See the Power Window Switch Continuity charts to determine if the continuity is correct in the Off, Up and Down switch positions . If OK, Refer to POWER WINDOWS TESTING. If not OK, replace the faulty switch. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Removal Power Window Switch: Service and Repair Removal REMOVAL FRONT PASSENGER 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel 3. Remove the switch from the trim panel bezel. REAR PASSENGER 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Gently pry switch from door trim panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Removal > Page 17007 Power Window Switch: Service and Repair Installation INSTALLATION FRONT PASSENGER 1. Insert switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. REAR PASSENGER 1. Install switch to door trim panel 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest for Back Window Glass: > 23-011-07 > Mar > 07 > Body Power Back Window Glass Keeper Loose Back Window Glass: Customer Interest Body - Power Back Window Glass Keeper Loose NUMBER: 23-011-07 GROUP: Body DATE: March 30, 2007 SUBJECT: Power Backlite Sliding Window - Glass Keeper Loose OVERVIEW: This bulletin involves installing a replacement backlite glass keeper MODELS: 2006 - 2007 (DR/DH/D1) Ram Truck (1500/2500/3500) NOTE: This bulletin applies to vehicles equipped with a power slider rear backlite (sales code GFE). SYMPTOM/CONDITION: The customer may notice that the glass keeper on the rear backlite has separated from the glass. DIAGNOSIS: If the above condition is present perform the Repair Procedure PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Use care not to scratch or damage glass surface or blackout area beyond what is covered by the keeper foot print. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest for Back Window Glass: > 23-011-07 > Mar > 07 > Body Power Back Window Glass Keeper Loose > Page 17017 1. On the backlite stationary glass locate where the keeper is positioned (Fig. 1). 2. Remove old, loose urethane from the area under the keeper foot print. Make sure the remaining urethane has been trimmed to a level, smooth surface. 3. With sand paper or emery cloth, scuff the remaining urethane surface where the keeper is located. 4. Clean area of keeper with water and dry surface. 5. Fully close the power sliding window. 6. On the stationary glass, dry fit the new keeper to its normal position. The keeper should be centered in the middle of the blackout area. 7. Make sure that there is a 1 mm gap (0.040 inch) between the edge of the sliding glass and the edge of the keeper base. Make sure the sliding glass has been fully closed prior to measuring the 1 mm gap. 8. With the keeper properly positioned on the stationary glass, draw an outline of the keeper base on the glass blackout area with a pencil. NOTE: The technician may want to mask off the immediate area around the keeper outline to aid in possible removal of excess urethane (squeeze-out) after the new keeper is installed. 9. Fully open the power sliding window. 10. Apply approximately 2.5 grams of urethane to the keeper. Make sure the amount of urethane that is applied to the keeper fills the keeper cavity. There should be sufficient urethane applied to cover at least 80% of the keeper foot print area. 11. Using the outline made earlier as a guide, apply the keeper to the stationary glass. 12. Fully seat the keeper to the stationary glass to ensure that the urethane covers at least 80% of the keeper foot print area. 13. Use a piece of tape to hold the keeper in place. Allow the urethane to harden. 14. Carefully remove the tape and clean any excess urethane from the stationary glass. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest for Back Window Glass: > 23-011-07 > Mar > 07 > Body Power Back Window Glass Keeper Loose > Page 17018 15. Apply a temporary piece of tape to hold the keeper in place overnight. NOTE: Be careful not to disturb the keeper and hardening urethane when closing the power sliding window. 16. Remove the tape the following day. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest for Back Window Glass: > 23-010-07 > Mar > 07 > Body Water Leak Onto Rear Floor Area Back Window Glass: Customer Interest Body - Water Leak Onto Rear Floor Area NUMBER: 23-010-07 GROUP: Body DATE: March 24, 2007 SUBJECT: Water Leak Due To Small Void In Backlite Sealer OVERVIEW: This bulletin involves inspection and correction of a backlite sealer void. MODELS: 2006 - 2007 (DR/DH/D1) Ram Truck (1500 / 2500 / 3500) 2006 - 2007 (ND) Dakota SYMPTOM/CONDITION: The customer may experience the presence of water on or under the rear area floor carpet. DIAGNOSIS: This condition may be due to water leaking past a small void in the adhesive used to retain the backlite glass to the body panel. The backlite glass is retained to the vehicle body by urethane adhesive. If the water leak is due to a small void in the backlite glass adhesive then perform the Repair Procedure. NOTE: DO NOT replace the backlite glass because of a small void in the backlite glass adhesive. Due to the possibility of backlite glass breakage during the backlite removal process, it is recommended that a flowable sealer be applied to seal a small void in the backlite adhesive. PARTS REQUIRED: REPAIR PROCEDURE: 1. Along the outside backlite-to-body panel urethane adhesive joint, dry off the affected area(s) with clean compressed air. 2. From outside the vehicle, apply Silicone Windshield and Glass Sealer to the affected area(s) in the backlite urethane adhesive joint. 3. Allow sufficient time to allow the newly applied sealer to dry. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest for Back Window Glass: > 23-010-07 > Mar > 07 > Body Water Leak Onto Rear Floor Area > Page 17023 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 23-011-07 > Mar > 07 > Body - Power Back Window Glass Keeper Loose Back Window Glass: All Technical Service Bulletins Body - Power Back Window Glass Keeper Loose NUMBER: 23-011-07 GROUP: Body DATE: March 30, 2007 SUBJECT: Power Backlite Sliding Window - Glass Keeper Loose OVERVIEW: This bulletin involves installing a replacement backlite glass keeper MODELS: 2006 - 2007 (DR/DH/D1) Ram Truck (1500/2500/3500) NOTE: This bulletin applies to vehicles equipped with a power slider rear backlite (sales code GFE). SYMPTOM/CONDITION: The customer may notice that the glass keeper on the rear backlite has separated from the glass. DIAGNOSIS: If the above condition is present perform the Repair Procedure PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Use care not to scratch or damage glass surface or blackout area beyond what is covered by the keeper foot print. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 23-011-07 > Mar > 07 > Body - Power Back Window Glass Keeper Loose > Page 17029 1. On the backlite stationary glass locate where the keeper is positioned (Fig. 1). 2. Remove old, loose urethane from the area under the keeper foot print. Make sure the remaining urethane has been trimmed to a level, smooth surface. 3. With sand paper or emery cloth, scuff the remaining urethane surface where the keeper is located. 4. Clean area of keeper with water and dry surface. 5. Fully close the power sliding window. 6. On the stationary glass, dry fit the new keeper to its normal position. The keeper should be centered in the middle of the blackout area. 7. Make sure that there is a 1 mm gap (0.040 inch) between the edge of the sliding glass and the edge of the keeper base. Make sure the sliding glass has been fully closed prior to measuring the 1 mm gap. 8. With the keeper properly positioned on the stationary glass, draw an outline of the keeper base on the glass blackout area with a pencil. NOTE: The technician may want to mask off the immediate area around the keeper outline to aid in possible removal of excess urethane (squeeze-out) after the new keeper is installed. 9. Fully open the power sliding window. 10. Apply approximately 2.5 grams of urethane to the keeper. Make sure the amount of urethane that is applied to the keeper fills the keeper cavity. There should be sufficient urethane applied to cover at least 80% of the keeper foot print area. 11. Using the outline made earlier as a guide, apply the keeper to the stationary glass. 12. Fully seat the keeper to the stationary glass to ensure that the urethane covers at least 80% of the keeper foot print area. 13. Use a piece of tape to hold the keeper in place. Allow the urethane to harden. 14. Carefully remove the tape and clean any excess urethane from the stationary glass. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 23-011-07 > Mar > 07 > Body - Power Back Window Glass Keeper Loose > Page 17030 15. Apply a temporary piece of tape to hold the keeper in place overnight. NOTE: Be careful not to disturb the keeper and hardening urethane when closing the power sliding window. 16. Remove the tape the following day. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 23-010-07 > Mar > 07 > Body - Water Leak Onto Rear Floor Area Back Window Glass: All Technical Service Bulletins Body - Water Leak Onto Rear Floor Area NUMBER: 23-010-07 GROUP: Body DATE: March 24, 2007 SUBJECT: Water Leak Due To Small Void In Backlite Sealer OVERVIEW: This bulletin involves inspection and correction of a backlite sealer void. MODELS: 2006 - 2007 (DR/DH/D1) Ram Truck (1500 / 2500 / 3500) 2006 - 2007 (ND) Dakota SYMPTOM/CONDITION: The customer may experience the presence of water on or under the rear area floor carpet. DIAGNOSIS: This condition may be due to water leaking past a small void in the adhesive used to retain the backlite glass to the body panel. The backlite glass is retained to the vehicle body by urethane adhesive. If the water leak is due to a small void in the backlite glass adhesive then perform the Repair Procedure. NOTE: DO NOT replace the backlite glass because of a small void in the backlite glass adhesive. Due to the possibility of backlite glass breakage during the backlite removal process, it is recommended that a flowable sealer be applied to seal a small void in the backlite adhesive. PARTS REQUIRED: REPAIR PROCEDURE: 1. Along the outside backlite-to-body panel urethane adhesive joint, dry off the affected area(s) with clean compressed air. 2. From outside the vehicle, apply Silicone Windshield and Glass Sealer to the affected area(s) in the backlite urethane adhesive joint. 3. Allow sufficient time to allow the newly applied sealer to dry. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 23-010-07 > Mar > 07 > Body - Water Leak Onto Rear Floor Area > Page 17035 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Backlite Back Window Glass: Service and Repair Backlite Removal REMOVAL CAUTION: It is difficult to salvage the backlite during the removal operation. The backlite is part of the structural support for the roof. The urethane bonding used to secure the glass to the fence is difficult to cut or clean from any surface. Since the molding is set in urethane, it is unlikely it would be salvaged. Before removing the backlite, check the availability from the parts supplier. NOTE: The backlite is attached to the window frame with urethane adhesive. The urethane adhesive is applied cold and seals the surface area between the window opening and the glass. The primer adheres the urethane adhesive to the backlite. 1. Roll down door glass. 2. Remove headliner (9). 3. On standard cab models remove the upper b-pillar trim (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Backlite > Page 17038 4. On quad cab models remove the upper c-pillar trim (5). 5. Bend backlite retaining tab (2) inward against glass. 6. Disconnect the rear window defogger electrical connector (if equipped). 7. Using a suitable pneumatic knife from inside the vehicle, cut urethane holding backlite frame to opening fence. 8. Separate glass (1) from vehicle. Installation INSTALLATION 1. Clean urethane adhesive from around backlite opening fence. 2. If necessary, apply black-out primer to outer edge of replacement backlite frame (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Backlite > Page 17039 3. If black-out primer was pre-applied on backlite, clean bonding surface with Isopropyl alcohol and clean lint free cloth. Allow 3 minutes for drying time. 4. Apply black-out primer to backlite opening fence. 5. Apply a 13 mm (0.5 in.) bead of urethane (4) around the perimeter of the window frame bonding surface (1). 6. Set glass (1) on lower fence and move glass forward into opening. 7. Firmly push glass (1) against rear window glass opening fence. 8. Bend tabs around edges of backlite opening fence to retain glass. 9. Clean excess urethane from exterior with MOPAR(R), Super Clean or equivalent. 10. Allow urethane to cure at least 24 hours (full cure is 72 hours). 11. Water test to verify repair before returning vehicle to service. 12. Connect the rear window defogger electrical connector, if equipped. 13. On standard cab models, install the upper b-pillar trim (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Backlite > Page 17040 14. On quad cab models, install the upper c-pillar trim (5). 15. Install the headliner (9). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Backlite > Page 17041 Back Window Glass: Service and Repair Backlite Vent Glass Removal REMOVAL 1. Slide the upper run channel (1) out of the window frame (2). 2. Slide the vent glass (3) upward to remove from the lower window frame (2). 3. Lower the glass (3) out of the upper window frame (2) and remove. Installation INSTALLATION 1. Slide the vent glass (3) upper edge into window frame (2) and insert the lower edge into the lower molding. 2. Position the upper run channel (1) into the window frame (2) and slide it into place. 3. Verify vent glass (3) operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding Front Door Window Glass Weatherstrip: Service and Repair Front Door Outer Belt Molding Removal REMOVAL 1. Remove the screw (4) and separate the belt molding (1) from the door (5) flange from the back to the front. Installation INSTALLATION 1. Position the belt molding (1) onto the door (5) flange and seat fully. 2. Install the screw (4). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 17047 Front Door Window Glass Weatherstrip: Service and Repair Front Door Glass Run Weatherstrip Removal REMOVAL 1. Remove the door glass. 2. Separate the front door glass run weatherstrip (2) out of the door frame (5) and remove through the window opening. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 17048 NOTE: A mixture of soap and water may be used to aid installation of the weatherstrip into the corners. 1. Position the front door glass run weatherstrip (2) into the door (5) through the window opening. 2. Position the weatherstrip into the upper corners and seat firmly. 3. From back to front, seat the weatherstrip between the corners and then down the sides firmly. 4. Install the door glass. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 17049 Front Door Window Glass Weatherstrip: Service and Repair Front Door Inner Belt Molding Removal REMOVAL 1. Remove the door trim panel (3). 2. Separate the belt molding (1) from the door (3) mounting flange from the back to the front. Installation INSTALLATION 1. Position the belt molding (1) and seat onto the door (3) mounting flange fully. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 17050 2. Install the door trim panel (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Outer Belt Molding Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Outer Belt Molding Removal REMOVAL 1. Remove the screw (3) and separate the belt molding (1) from the door (2) flange from the back to the front. Installation INSTALLATION 1. Position the belt molding (1) onto the door (2) flange and seat fully. 2. Install the screw (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Outer Belt Molding > Page 17056 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Run Weatherstrip Removal REMOVAL 1. Lower the glass. 2. Separate the rear door glass run weatherstrip (5) out of the door frame (2) and remove through the window opening. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Outer Belt Molding > Page 17057 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Outer Belt Molding > Page 17058 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Inner Belt Molding Removal REMOVAL 1. Remove the door trim panel (5). 2. Separate the belt molding (2) from the rear door mounting flange from the back to the front. Installation INSTALLATION 1. Position the belt molding (2) and seat onto the rear door mounting flange fully. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Rear Door Outer Belt Molding > Page 17059 2. Install the door trim panel (5). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Back Window Regulator > Component Information > Service and Repair > Removal Back Window Regulator: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the rear seats. 3. Remove the rear cab back panel. 4. Remove the two mounting bolts (1). 5. Disconnect the electrical connector to the power motor. 6. Separate the cable housings from the glass track (1). 7. Disconnect the cable ends from the vent glass (2). 8. Separate the support clips (5) and remove the regulator assembly (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Back Window Regulator > Component Information > Service and Repair > Removal > Page 17065 Back Window Regulator: Service and Repair Installation INSTALLATION 1. Connect the cable ends to the vent glass (2). 2. Install the cable housings into the glass tracks (1). 3. Fasten the support clips (5). 4. Install the 2 mounting bolts (1). 5. Install the rear cab back panel. 6. Install the rear seats. 7. Connect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Power Front Door Window Regulator: Service and Repair Front Door Window Regulator - Power Removal REMOVAL 1. Remove the inner belt molding. 2. Remove the waterdam. 3. Remove the electric window switch from the door trim panel and connect it to the door wire harness. 4. Raise the door glass to the position shown. 5. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 6. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 7. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 8. Remove the bolt (5) that secures the window regulator to the door and loosen the other two regulator bolts (7). 9. Slide the window regulator upward and disengage the two regulator bolts from the door. 10. Remove the window regulator through the opening in the door and disconnect the door wire harness (6). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Power > Page 17070 Installation INSTALLATION 1. Connect the door wire harness (6) to the window regulator (4) and install the regulator through the opening in the door (2). 2. Engage the two regulator bolts (7) to the door. 3. Install the bolt (5) that secure the window regulator to the door and tighten all three regulator bolts to 10 Nm (89 in. lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 Nm (89 in. lbs.). 5. Raise the window regulator (2) to the position shown. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 Nm (89 in. lbs.). 8. Disconnect the electric window switch from the door wire harness and reinstall the switch onto the door trim panel. 9. Install the waterdam. 10. Install the inner belt molding. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Power > Page 17071 Front Door Window Regulator: Service and Repair Front Door Window Regulator - Manual Removal REMOVAL 1. Remove the inner belt molding. 2. Remove the waterdam. 3. Reinstall the manual window crank and raise the door glass to the position shown. 4. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 5. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 6. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 7. Remove the two bolts (5) that secure the window regulator to the door and loosen the other two regulator bolts (6). 8. Slide the window regulator upward and disengage the two regulator bolts from the door. 9. Remove the window regulator through the opening in the door. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Power > Page 17072 1. Install the window regulator (4) through the opening in the door (2). 2. Engage the two regulator bolts (6) to the door. 3. Install the two bolt (5) that secure the window regulator to the door and tighten all four regulator bolts to 10 Nm (89 in. lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 Nm (89 in. lbs.). 5. Raise the window regulator (2) to the position shown and remove the manual window crank. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 Nm (89 in. lbs.). 8. Install the waterdam. 9. Install the inner belt molding. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Window Regulator - Power Rear Door Window Regulator: Service and Repair Window Regulator - Power Removal REMOVAL 1. Remove the inner belt molding. 2. Remove the waterdam. 3. Remove the electric window switch from the door trim panel and connect it to the door wire harness. 4. Raise the door glass to the position shown. 5. Remove the two nuts (1) that secure the door glass (2) to the window regulator (3) through the speaker opening (5) and the sight window (4) and disengage the door glass from the regulator. 6. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 7. Lower the window regulator and remove the two nuts (1) that secure the regulator stabilizer to the door. 8. Remove the bolts (2) that secures the window regulator to the door and loosen the other two regulator bolts (3). 9. Slide the window regulator upward and disengage the two regulator bolts from the door. 10. Remove the window regulator through the opening in the door and disconnect the door wire harness (4). Installation Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Window Regulator - Power > Page 17077 INSTALLATION 1. Connect the door wire harness (4) to the window regulator and install the regulator through the opening in the door. 2. Engage the two regulator bolts (3) to the door. 3. Install the regulator bolts (2) that secures the window regulator to the door and tighten all regulator bolts to 10 Nm (89 in. lbs.). 4. Position the regulator stabilizer into the door and install the two nuts. Tighten the nuts to 10 Nm (89 in. lbs.). 5. Raise the window regulator (3) to the position shown. 6. Support the door glass (2) and remove the wooden wedge or equivalent. 7. Position the door glass to the window regulator and install the two nuts (1) that secure the door glass to the window regulator (3) through the sight window (4) and the speaker opening (5). Tighten the nuts to 10 Nm (89 in. lbs.). 8. Disconnect the electric window switch from the door wire harness and reinstall the switch onto the door trim panel. 9. Install the waterdam. 10. Install the inner belt molding. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Window Regulator - Power > Page 17078 Rear Door Window Regulator: Service and Repair Window Regulator - Manual Removal REMOVAL 1. Remove the inner belt molding. 2. Remove the waterdam. 3. Reinstall the manual window crank and raise the door glass to the position shown. 4. Remove the two nuts (1) that secure the door glass (2) to the window regulator (3) through the speaker opening (5) and the sight window (4) and disengage the door glass from the regulator. 5. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 6. Lower the window regulator (5) and remove the two nuts (3) that secure the regulator stabilizer (4) to the door (1). 7. Remove the two bolts (2) that secure the window regulator to the door and loosen the other two regulator bolts (6). 8. Slide the window regulator upward and disengage the two regulator bolts from the door. 9. Remove the window regulator through the opening in the door. Installation INSTALLATION Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Window Regulator - Power > Page 17079 1. Install the window regulator (5) through the opening in the door (1). 2. Engage the two regulator bolts (6) to the door. 3. Install the two bolts (2) that secure the window regulator to the door and tighten all four regulator bolts to 10 Nm (89 in. lbs.). 4. Position the regulator stabilizer (4) onto the door and install the two nuts (3). Tighten the nuts to 10 Nm (89 in. lbs.). 5. Raise the window regulator (3) to the position shown and remove the manual window crank. 6. Support the door glass (2) and remove the wooden wedge or equivalent. 7. Position the door glass to the window regulator and install the two nuts (1) that secure the door glass to the window regulator through the sight window (4) and the speaker opening (5). Tighten the nuts to 10 Nm (89 in. lbs.). 8. Install the waterdam. 9. Install the inner belt molding. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest for Window Seal: > 23-010-07 > Mar > 07 > Body - Water Leak Onto Rear Floor Area Window Seal: Customer Interest Body - Water Leak Onto Rear Floor Area NUMBER: 23-010-07 GROUP: Body DATE: March 24, 2007 SUBJECT: Water Leak Due To Small Void In Backlite Sealer OVERVIEW: This bulletin involves inspection and correction of a backlite sealer void. MODELS: 2006 - 2007 (DR/DH/D1) Ram Truck (1500 / 2500 / 3500) 2006 - 2007 (ND) Dakota SYMPTOM/CONDITION: The customer may experience the presence of water on or under the rear area floor carpet. DIAGNOSIS: This condition may be due to water leaking past a small void in the adhesive used to retain the backlite glass to the body panel. The backlite glass is retained to the vehicle body by urethane adhesive. If the water leak is due to a small void in the backlite glass adhesive then perform the Repair Procedure. NOTE: DO NOT replace the backlite glass because of a small void in the backlite glass adhesive. Due to the possibility of backlite glass breakage during the backlite removal process, it is recommended that a flowable sealer be applied to seal a small void in the backlite adhesive. PARTS REQUIRED: REPAIR PROCEDURE: 1. Along the outside backlite-to-body panel urethane adhesive joint, dry off the affected area(s) with clean compressed air. 2. From outside the vehicle, apply Silicone Windshield and Glass Sealer to the affected area(s) in the backlite urethane adhesive joint. 3. Allow sufficient time to allow the newly applied sealer to dry. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest for Window Seal: > 23-010-07 > Mar > 07 > Body - Water Leak Onto Rear Floor Area > Page 17088 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Seal: > 23-010-07 > Mar > 07 > Body - Water Leak Onto Rear Floor Area Window Seal: All Technical Service Bulletins Body - Water Leak Onto Rear Floor Area NUMBER: 23-010-07 GROUP: Body DATE: March 24, 2007 SUBJECT: Water Leak Due To Small Void In Backlite Sealer OVERVIEW: This bulletin involves inspection and correction of a backlite sealer void. MODELS: 2006 - 2007 (DR/DH/D1) Ram Truck (1500 / 2500 / 3500) 2006 - 2007 (ND) Dakota SYMPTOM/CONDITION: The customer may experience the presence of water on or under the rear area floor carpet. DIAGNOSIS: This condition may be due to water leaking past a small void in the adhesive used to retain the backlite glass to the body panel. The backlite glass is retained to the vehicle body by urethane adhesive. If the water leak is due to a small void in the backlite glass adhesive then perform the Repair Procedure. NOTE: DO NOT replace the backlite glass because of a small void in the backlite glass adhesive. Due to the possibility of backlite glass breakage during the backlite removal process, it is recommended that a flowable sealer be applied to seal a small void in the backlite adhesive. PARTS REQUIRED: REPAIR PROCEDURE: 1. Along the outside backlite-to-body panel urethane adhesive joint, dry off the affected area(s) with clean compressed air. 2. From outside the vehicle, apply Silicone Windshield and Glass Sealer to the affected area(s) in the backlite urethane adhesive joint. 3. Allow sufficient time to allow the newly applied sealer to dry. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Seal: > 23-010-07 > Mar > 07 > Body - Water Leak Onto Rear Floor Area > Page 17094 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair > Removal Window Track: Service and Repair Removal Front-All Models FRONT-ALL MODELS 1. Raise the window glass to the full up position and remove the window regulator. 2. Loosen the two bolts (2 and 3) that secure the front glass run channel (1) to the door (5). 3. Slide the front glass run channel upward and disengage it from the door. 4. Remove the front glass run channel from the door through the door panel opening (4). 5. If required, remove the weatherstrip from the front glass run channel. Rear-Quad Cab REAR-QUAD CAB 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the lower bolt (1) that secures the rear glass run channel (3) to the door. 3. Loosen the upper bolt (4) that secures the rear glass run channel to the door. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair > Removal > Page 17099 4. Slide the rear glass run channel upward and disengage the upper screw from the door. 5. Remove the rear glass run channel from the door through the door panel opening (2). 6. If required, remove the weatherstrip from the rear glass run channel. Rear-Standard Cab REAR-STANDARD CAB 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1) that secure the rear glass run channel (2) to the door. 3. Remove the rear glass run channel from the door through the door panel opening (3). 4. If required, remove the weatherstrip from the rear glass run channel. Front FRONT 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1) that secure the front glass run channel (2) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the front glass run channel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair > Removal > Page 17100 Mega Cab Models 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1 & 3) that secure the front glass run channel (2) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the front glass run channel. Rear REAR 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (2) that secure the rear glass run channel (1) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the rear glass run channel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair > Removal > Page 17101 Window Track: Service and Repair Installation Front-All Models FRONT-ALL MODELS 1. If removed, install the weatherstrip onto the front glass run channel (1). 2. Position the front glass run channel into the door (5) through the door panel opening (4). 3. Engage the two bolts (2 and 3) that secure the front glass run channel to the door. Tighten the bolts to 10 Nm (89 in. lbs.). 4. Install the window regulator and verify correct window operation. Rear-Quad Cab REAR-QUAD CAB 1. If removed, install the weatherstrip onto the rear glass run channel (3). 2. Position the rear glass run channel into the door through the door panel opening (2). 3. Engage the upper bolt (4) that secures the rear glass run channel to the door. 4. Install the lower bolt (1) that secures the rear glass run channel to the door. Tighten both the upper and lower bolts to 10 Nm (89 in. lbs.). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair > Removal > Page 17102 5. Install the window regulator and verify correct window operation. Rear-Standard Cab REAR-STANDARD CAB 1. If removed, install the weatherstrip onto the rear glass run channel (2). 2. Position the rear glass run channel into the door through the door panel opening (3). 3. Install the two bolts (1) that secure the rear glass run channel to the door. Tighten the bolts to 10 Nm (89 in. lbs.). 4. Install the window regulator and verify correct window operation. Front FRONT 1. If removed, install the weatherstrip onto the front glass run channel (2). 2. Position the front glass run channel into the door through the door panel opening. 3. Install the two bolts (1) that secure the front glass run channel to the door. Tighten the bolts to 10 Nm (89 in. lbs.). 4. Install the window regulator and verify correct window operation. Mega Cab Models Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair > Removal > Page 17103 1. If removed, install the weatherstrip onto the front glass run channel (2). 2. Position the front glass run channel into the door through the door panel opening. 3. Install the two bolts (1 & 3) that secure the front glass run channel to the door. Tighten the bolts to 10 Nm (89 in. lbs.). 4. Install the window regulator and verify correct window operation. Rear REAR 1. If removed, install the weatherstrip onto the rear glass run channel (1). 2. Position the rear glass run channel into the door through the door panel opening. 3. Install the two bolts (2) that secure the rear glass run channel to the door. Tighten the bolts to 10 Nm (89 in. lbs.). 4. Install the window regulator and verify correct window operation. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Body - Windshield Crack Diagnosis Windshield: Technical Service Bulletins Body - Windshield Crack Diagnosis NUMBER: 23-047-06 GROUP: Body DATE: October 21, 2006 SUBJECT: Cracked Windshield MODELS: 2006 - 2007 (CS) Pacifica 2006 - 2007 (DC) Ram Cab & Chassis 2006 - 2007 (DR/DH/D1) Ram Truck 2006 - 2007 (HB) Durango 2007 (HG) Aspen 2006 (TJ) Wrangler/Wrangler Unlimited 2007 (JK) Wrangler/Wrangler Unlimited 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 2007 (KA) Nitro 2006 - 2007 (KJ) Liberty/Cherokee 2006 - 2007 (LE) 300C/300C Touring (International Market) 2006 - 2007 (LX) 300/Magnum/Charger 2007 (MK49) Compass 2006 - 2007 (ND) Dakota 2007 (PM) Caliber 2006 - 2007 (PT) Chrysler PT Cruiser 2006 - 2007 (RS) Town & Country/Caravan 2006 - 2007 (RG) Chrysler Voyager (International Market) 2006 - 2007 (WK) Grand Cherokee 2006 - 2007 (WH) Grand Cherokee (International Market) 2006 - 2007 (XK/XH) Commander 2006 (ZB) Viper 2006 - 2007 (ZH) Crossfire DISCUSSION: Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Body - Windshield Crack Diagnosis > Page 17108 Windshield cracks caused by an impact from a foreign object; (i.e. stone) are often difficult to identify. The following assessment should be used to verify the presence of an impact chip on the crack. If no obvious impact chip is present, run a ball point pen along the crack and feel for a slight drop or pit in the glass. If a slight drop or pit in the glass is present, this indicates a small impact caused the crack. If the molding contains a witness mark or dent from an impact, inspect under the molding for an impact chip in the same manner. POLICY: Cracks caused by an impact are not warrantable. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 17109 Windshield: Service Precautions WINDSHIELD SAFETY PRECAUTIONS Do not operate the vehicle within 24 hours of windshield installation. It takes at least 24 hours for urethane adhesive to cure. If it is not cured, the windshield may not perform properly in an accident. Urethane adhesives are applied as a system. Use glass cleaner, glass prep solvent, glass primer, PVC (vinyl) primer and pinch weld (fence) primer provided by the adhesive manufacturer. If not, structural integrity could be compromised. DaimlerChrysler does not recommend glass adhesive by brand. Technicians should review product labels and technical data sheets, and use only adhesives that their manufactures warranty and will restore a vehicle to the requirements of FMVSS 212. Technicians should also insure that primers and cleaners are compatible with the particular adhesive used. Be sure to refer to the urethane manufacturer's directions for curing time specifications and do not use adhesive after its expiration date. Vapors that are emitted from the urethane adhesive or primer could cause personal injury or death. Use them in a well-ventilated area. Skin contact with urethane adhesive should be avoided. Personal injury or death may result. Always wear eye and hand protection when working with glass. Protect all painted and trimmed surfaces from coming in contact with urethane or primers. Be careful not to damage painted surfaces when removing moldings or cutting urethane around windshield. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Removal Windshield: Service and Repair Removal REMOVAL 1. Remove inside rear view mirror (3). 2. Remove cowl grille (2). 3. Remove the a-pillar weatherstrip retainer (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Removal > Page 17112 4. Remove the a-pillar trim panels (2). 5. Remove the headliner (9) and from the inside of the vehicle, cut the upper urethane bonding from around windshield upper edge using a suitable sharp cold knife (C-4849). A pneumatic cutting device can be used but is not recommended. 6. From the outside of the vehicle, cut urethane bonding from the remaining sides of the windshield using a suitable sharp cold knife (C-4849). A pneumatic cutting device can be used but is not recommended. 7. Separate windshield from vehicle. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Removal > Page 17113 Windshield: Service and Repair Installation INSTALLATION WARNING: Allow the urethane at least 24 hours to cure before returning the vehicle to use. CAUTION: Roll down the left and right front door glass and open the rear glass slider (if available) before installing windshield. This is to avoid pressurizing the passenger compartment if a door is slammed before the urethane is cured. The potential for water leaks can result. The windshield fence should be cleaned of most of its old urethane bonding material. A small amount of old urethane, approximately 1-2 mm in height, should remain on the fence. Do not grind off or completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected. 1. Place replacement windshield (1) into windshield opening and position glass in the center of the opening against the support spacers (3). Mark the outside surface of the glass at the support spacers (3) with a grease pencil or pieces of masking tape and ink pen to use as a reference (2) for installation. Remove replacement windshield from windshield opening. 2. Position the windshield (1) inside up on a suitable work surface with two padded, wood 10 cm by 10 cm by 50 cm (4 in. by 4 in. by 20 in.) blocks (3), placed parallel 75 cm (2.5 ft.) apart. 3. Clean inside of windshield with MOPAR(R) Glass Cleaner and lint-free cloth. 4. Apply clear glass primer 25 mm (1 in.) wide around perimeter of windshield and wipe with a new clean and dry lint- free cloth. 5. Apply black-out primer onto the glass using the windshield molding as a guide. The primer should be 15 mm (5/8 in.) wide on the top and sides of the glass and 25 mm (1 in.) on the bottom of windshield. Allow at least three minutes drying time. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Removal > Page 17114 6. Locate NEW support spacers (3) on support brackets and adjust to lowest height. 7. Position seven new foam spacers (4 and 3) on the inside surface of the windshield, flush with the lower and side edges. 8. Position three new foam spacers (1) on the inside surface of the windshield, at a minimum distance of 3 mm (0.12 in.) from the top edge of the windshield. 9. The urethane bead should be shaped in a triangular cross-section, this can be achieved by notching the tip of the applicator. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Removal > Page 17115 10. Apply a 13 mm (1/2 in.) high and 10 mm (3/8 in.) wide bead of urethane around the perimeter of windshield (2). At the top, apply the bead 7 mm (1/4 in.) inboard from the glass edge. On the other three sides apply the bead 14 mm (0.55 in.) inboard from the glass edge. 11. Install the a-pillar trim (2). 12. With the aid of a helper, position the windshield (2) over the windshield opening. Align the reference marks at the bottom of the windshield to the support spacers (3). 13. Slowly lower windshield glass (2) to the fence opening guiding the lower corners into proper position. Beginning at the bottom and continuing to the top, push glass (2) onto fence along the A-Pillars. Push windshield (2) inward to the fence at the bottom corners. 14. Push windshield (2) upward, setting the windshield to roof gap to 1.5 mm (0.06 in.) to 3 mm (0.12 in.) and ratchet up the adjustable support brackets. 15. Using clean water, lightly mist the support spacers (3). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Removal > Page 17116 16. Clean excess urethane from exterior with MOPAR(R) Super Clean or equivalent. 17. Install cowl grille (2). 18. Install rear view mirror support bracket (4). 19. Install rear view mirror (3). 20. Install the a-pillar weatherstrip retainer (1). 21. After urethane has cured, remove tape strips and water test windshield to verify repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Description and Operation > Description Check Valve: Description and Operation Description DESCRIPTION A single washer system check valve is standard equipment on this vehicle, and is installed in the washer system plumbing. The check valve is integral to the washer nozzle plumbing wye fitting (2) located in the cowl plenum area beneath the cowl plenum cover/grille panel near the base of the windshield. The check valve consists of a molded plastic body with a raised arrowhead (4) molded into its center that indicates the direction of the flow through the valve, and three barbed hose nipples (1 and 3) formed in a wye configuration on the outside circumference of the center of the valve body. The check valve cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Description and Operation > Description > Page 17122 Check Valve: Description and Operation Operation OPERATION The check valve provides more than one function in this application. It serves as a wye connector fitting between the engine compartment and washer nozzle sections of the washer supply hose. It prevents washer fluid from draining out of the washer supply hoses back to the washer reservoir. This drain-back would result in a lengthy delay from when the washer switch is actuated until washer fluid was dispensed through the washer nozzles, because the washer pump would have to refill the washer plumbing from the reservoir to the nozzles. Such a drain-back condition could also result in water, dirt, or other outside contaminants being siphoned into the washer system through the washer nozzle orifice. This water could subsequently freeze and plug the nozzle, while other contaminants could interfere with proper nozzle operation and cause improper nozzle spray patterns. In addition, the check valve prevents washer fluid from siphoning through the washer nozzles after the washer system is turned OFF. When the washer pump pressurizes and pumps washer fluid from the reservoir through the washer plumbing, the fluid pressure (5) unseats a diaphragm (3) from over a sump well within the valve by overriding the pressure applied to a piston (2) by a spring (1). With the diaphragm unseated, washer fluid is allowed to flow toward the two washer nozzles (4). When the washer pump stops operating, the spring pressure on the piston seats the diaphragm over the sump well in the valve and fluid flow in either direction within the washer plumbing is prevented. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Service and Repair > Removal Check Valve: Service and Repair Removal REMOVAL 1. Remove both wiper arms from the wiper pivots. 2. Unlatch and open the hood. 3. Remove the cowl plenum cover/grille panel from over the cowl plenum. 4. From the underside of the cowl plenum cover/grille panel (5), disconnect the cowl plenum (4) and washer nozzle hoses (1 and 6) from the three barbed nipples of the check valve (2). 5. Remove the check valve from the underside of the cowl plenum cover/grille panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Service and Repair > Removal > Page 17125 Check Valve: Service and Repair Installation INSTALLATION 1. Position the check valve (2) to the underside of the cowl plenum cover/grille panel (5). Be certain that the flow direction arrow molded into the check valve body is oriented towards the washer nozzles. 2. From the underside of the cowl plenum cover/grille panel, reconnect the cowl plenum (4) and washer nozzle hoses (1 and 6) to the three barbed nipples of the check valve. 3. Reinstall the cowl plenum cover/grille panel over the cowl plenum. 4. Close and latch the hood. 5. Reinstall both wiper arms onto the wiper pivots. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Dodge Ram 2006-2008, 1500-5500 all, do not use a wiper relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 17130 Wiper Relay: Description and Operation Dodge Ram 2006-2009, does not use a wiper relay. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations Component ID: 492 Component : SWITCH-WASHER FLUID LEVEL Connector: Name : SWITCH-WASHER FLUID LEVEL Color : LT. GRAY # of pins : 2 Pin Description Circuit 1 WASHER FLUID SWITCH RETURN G932 20VT/TN 2 WASHER FLUID SWITCH SENSE W1 20BR/TN Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 17135 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 17136 Washer Fluid Level Switch: Diagrams Component ID: 492 Component : SWITCH-WASHER FLUID LEVEL Connector: Name : SWITCH-WASHER FLUID LEVEL Color : LT. GRAY # of pins : 2 Pin Description Circuit 1 WASHER FLUID SWITCH RETURN G932 20VT/TN 2 WASHER FLUID SWITCH SENSE W1 20BR/TN Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 17137 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Description Washer Fluid Level Switch: Description and Operation Description DESCRIPTION The washer fluid level switch (3) is a two-pin conductivity sensor with no moving parts mounted on the rearward facing side of the washer reservoir adjacent to the washer pump/motor unit in the engine compartment. Only the molded plastic switch mounting flange and the integral connector receptacle (4) are visible when the switch is installed in the reservoir. A short nipple formation (1) extends from the inner surface of the switch mounting flange, and a barb on the nipple is pressed through a rubber grommet seal installed in the mounting hole of the reservoir. Two over-molded pins or electrodes (2) extend from the back of the nipple formation. The washer fluid level switch cannot be adjusted or repaired. If ineffective or damaged, the switch must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Description > Page 17140 Washer Fluid Level Switch: Description and Operation Operation OPERATION The washer fluid level switch uses fluid conductivity to monitor the level of the washer fluid in the washer reservoir. Electricity is conducted between the two switch pins or electrodes only when they are immersed in the washer fluid, which closes the switch circuit. When the fluid level in the washer reservoir falls below the pins, electrical current cannot be conducted and the switch becomes an open circuit, which signals a low fluid condition. In order to prevent an electrical charge from accumulating in the electrical leads of the switch, the switch receives current that is pulsed from the Totally Integrated Power Module (TIPM) located in the engine compartment near the battery. The TIPM monitors the switch return signal and is programmed to respond to three consecutive open switch readings by sending an electronic washer fluid indicator lamp-ON message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) over the Controller Area Network (CAN) data bus. The EMIC responds to this message by illuminating the washer fluid indicator and by sounding an audible chime tone warning. The washer fluid level switch is connected to the vehicle electrical system through a dedicated take out and connector of the right (gasoline engines) or left (diesel engines) headlamp and dash wire harness. The switch is connected in series between a sensor return circuit and the washer fluid switch sense input to the TIPM. The washer fluid level switch and the hard wired circuits between the switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the washer fluid level switch or the electronic controls or communication between other modules and devices that provide some features of the wiper and washer systems. The most reliable, efficient, and accurate means to diagnose the washer fluid level switch or the electronic controls and communication related to washer fluid level switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Service and Repair > Removal Washer Fluid Level Switch: Service and Repair Removal DIESEL ENGINE NOTE: The washer fluid level switch can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the washer hose (4) from the barbed outlet nipple of the washer pump/motor unit (3) and allow the washer fluid to drain into a clean container for reuse. 3. Disconnect the left headlamp and dash wire harness (1) connector for the washer fluid level switch (5) from the switch connector receptacle. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal in the washer reservoir sump (2). Care must be taken not to damage the reservoir. 5. Remove the switch from the reservoir. 6. Remove the rubber grommet seal from the mounting hole in the washer reservoir and discard. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Service and Repair > Removal > Page 17143 Washer Fluid Level Switch: Service and Repair Installation DIESEL ENGINE 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole in the washer reservoir (2). Always use a new rubber grommet seal on the reservoir. 2. Insert the nipple formation of the switch (5) through the rubber grommet seal and in the reservoir. 3. Using hand pressure, press firmly and evenly on the switch mounting flange until the barbed nipple is fully seated in the rubber grommet seal in the reservoir. The flat edge of the switch mounting flange should be pointed upward. 4. Reconnect the left headlamp and dash wire harness (1) connector for the switch to the switch connector receptacle. 5. Reconnect the removed washer hose (4) to the barbed outlet nipple of the washer pump/motor unit (3). 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Description and Operation > Description Washer Fluid Level Indicator: Description and Operation Description DESCRIPTION A washer fluid indicator is standard equipment on all instrument clusters. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The washer fluid indicator consists of a stencil-like cutout of the International Control and Display Symbol Icon for Windscreen Washer Fluid Level in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The washer fluid indicator is serviced as a unit with the instrument cluster. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Description and Operation > Description > Page 17148 Washer Fluid Level Indicator: Description and Operation Operation OPERATION The washer fluid indicator gives an indication to the vehicle operator that the fluid level in the washer reservoir is low. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The washer fluid indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the washer fluid indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the washer fluid indicator is illuminated for about two seconds as a bulb test. - Washer Fluid Indicator Lamp-On Message - Each time the cluster receives an electronic washer fluid indicator lamp-ON message from the TIPM indicating that a low washer condition has been detected for 60 consecutive seconds, the washer fluid indicator is illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives lamp-OFF messages for 60 consecutive seconds from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the washer fluid indicator is cycled OFF and then ON again by the appropriate lamp-ON and lamp-OFF messages from the TIPM. - Actuator Test - Each time the cluster is put through the actuator test, the washer fluid indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the washer fluid level switch in the washer reservoir to determine the level of the washer fluid. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). For proper diagnosis of the washer fluid level switch, the TIPM, the EMIC, the CAN data bus or the electronic communication related to washer fluid indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations Component ID: 492 Component : SWITCH-WASHER FLUID LEVEL Connector: Name : SWITCH-WASHER FLUID LEVEL Color : LT. GRAY # of pins : 2 Pin Description Circuit 1 WASHER FLUID SWITCH RETURN G932 20VT/TN 2 WASHER FLUID SWITCH SENSE W1 20BR/TN Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 17152 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 17153 Washer Fluid Level Switch: Diagrams Component ID: 492 Component : SWITCH-WASHER FLUID LEVEL Connector: Name : SWITCH-WASHER FLUID LEVEL Color : LT. GRAY # of pins : 2 Pin Description Circuit 1 WASHER FLUID SWITCH RETURN G932 20VT/TN 2 WASHER FLUID SWITCH SENSE W1 20BR/TN Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 17154 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Description Washer Fluid Level Switch: Description and Operation Description DESCRIPTION The washer fluid level switch (3) is a two-pin conductivity sensor with no moving parts mounted on the rearward facing side of the washer reservoir adjacent to the washer pump/motor unit in the engine compartment. Only the molded plastic switch mounting flange and the integral connector receptacle (4) are visible when the switch is installed in the reservoir. A short nipple formation (1) extends from the inner surface of the switch mounting flange, and a barb on the nipple is pressed through a rubber grommet seal installed in the mounting hole of the reservoir. Two over-molded pins or electrodes (2) extend from the back of the nipple formation. The washer fluid level switch cannot be adjusted or repaired. If ineffective or damaged, the switch must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Description > Page 17157 Washer Fluid Level Switch: Description and Operation Operation OPERATION The washer fluid level switch uses fluid conductivity to monitor the level of the washer fluid in the washer reservoir. Electricity is conducted between the two switch pins or electrodes only when they are immersed in the washer fluid, which closes the switch circuit. When the fluid level in the washer reservoir falls below the pins, electrical current cannot be conducted and the switch becomes an open circuit, which signals a low fluid condition. In order to prevent an electrical charge from accumulating in the electrical leads of the switch, the switch receives current that is pulsed from the Totally Integrated Power Module (TIPM) located in the engine compartment near the battery. The TIPM monitors the switch return signal and is programmed to respond to three consecutive open switch readings by sending an electronic washer fluid indicator lamp-ON message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) over the Controller Area Network (CAN) data bus. The EMIC responds to this message by illuminating the washer fluid indicator and by sounding an audible chime tone warning. The washer fluid level switch is connected to the vehicle electrical system through a dedicated take out and connector of the right (gasoline engines) or left (diesel engines) headlamp and dash wire harness. The switch is connected in series between a sensor return circuit and the washer fluid switch sense input to the TIPM. The washer fluid level switch and the hard wired circuits between the switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the washer fluid level switch or the electronic controls or communication between other modules and devices that provide some features of the wiper and washer systems. The most reliable, efficient, and accurate means to diagnose the washer fluid level switch or the electronic controls and communication related to washer fluid level switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Service and Repair > Removal Washer Fluid Level Switch: Service and Repair Removal DIESEL ENGINE NOTE: The washer fluid level switch can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the washer hose (4) from the barbed outlet nipple of the washer pump/motor unit (3) and allow the washer fluid to drain into a clean container for reuse. 3. Disconnect the left headlamp and dash wire harness (1) connector for the washer fluid level switch (5) from the switch connector receptacle. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal in the washer reservoir sump (2). Care must be taken not to damage the reservoir. 5. Remove the switch from the reservoir. 6. Remove the rubber grommet seal from the mounting hole in the washer reservoir and discard. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Service and Repair > Removal > Page 17160 Washer Fluid Level Switch: Service and Repair Installation DIESEL ENGINE 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole in the washer reservoir (2). Always use a new rubber grommet seal on the reservoir. 2. Insert the nipple formation of the switch (5) through the rubber grommet seal and in the reservoir. 3. Using hand pressure, press firmly and evenly on the switch mounting flange until the barbed nipple is fully seated in the rubber grommet seal in the reservoir. The flat edge of the switch mounting flange should be pointed upward. 4. Reconnect the left headlamp and dash wire harness (1) connector for the switch to the switch connector receptacle. 5. Reconnect the removed washer hose (4) to the barbed outlet nipple of the washer pump/motor unit (3). 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Description and Operation > Description Windshield Washer Hose: Description and Operation Description DESCRIPTION The washer plumbing consists of a small diameter rubber reservoir washer hose that is routed from the barbed outlet nipple of the electric washer pump/motor unit on the washer reservoir through a trough molded into the back of the reservoir above the washer pump to the engine compartment washer hose to the right side of the engine cooling module. On vehicles equipped with an optional diesel engine, the reservoir washer hose is routed through routing clips on the top of the radiator fan shroud from the washer reservoir on the left side of the radiator to the engine compartment washer hose on the right side of the radiator. The engine compartment washer hose is contained within the right headlamp and dash wire harness (2), which is routed through the engine compartment along the top of the right front fender wheel house to the dash panel. This hose is connected to the washer reservoir washer hose at one end (5) and to the cowl plenum washer hose at the other end (3) with molded plastic in-line fittings that have a barbed nipple on each end. The cowl plenum washer hose (4) is routed from the engine compartment into the cowl plenum area through a trough formation located near the right end of the cowl plenum cover/grille panel. The cowl plenum washer hose is connected to the washer system check valve/wye fitting on the underside of the cowl plenum cover/grille panel. The cowl plenum washer hose and the two washer nozzle hoses are routed through integral routing clips on the underside of the cowl plenum cover/grille panel. The cowl plenum washer hose is connected to one nipple on the wye fitting and the two washer nozzle hoses are connected to the other two nipples. The washer nozzle hoses are then routed along the underside of the cowl plenum cover/grille panel to the two washer nozzles. Washer hose is available for service only as roll stock, which must then be cut to length. The molded plastic washer hose fittings cannot be repaired. If these fittings are ineffective or damaged, they must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Description and Operation > Description > Page 17165 Windshield Washer Hose: Description and Operation Operation OPERATION Washer fluid in the washer reservoir is pressurized and fed by the washer pump/motor through the washer system plumbing and fittings to the two washer nozzles. Whenever routing the washer hose or a wire harness containing a washer hose, it must be routed away from hot, sharp, or moving parts; and, sharp bends that might pinch the hose must be avoided. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations Windshield Washer Pump: Locations Component ID: 237 Component : PUMP-WASHER-WINDSHIELD Connector: Name : PUMP-WASHER-WINDSHIELD Color : BLACK # of pins : 2 Pin Description Circuit 1 GROUND Z945 20BK 2 WASHER PUMP MOTOR CONTROL W10 20BR Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 17169 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 17170 Windshield Washer Pump: Diagrams Component ID: 237 Component : PUMP-WASHER-WINDSHIELD Connector: Name : PUMP-WASHER-WINDSHIELD Color : BLACK # of pins : 2 Pin Description Circuit 1 GROUND Z945 20BK 2 WASHER PUMP MOTOR CONTROL W10 20BR Component Location - 29 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 17171 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Description and Operation > Description Windshield Washer Pump: Description and Operation Description DESCRIPTION The washer pump/motor unit (1) is located on the rearward facing surface of the washer reservoir, in the right (gasoline engines) or left (diesel engines) front corner of the engine compartment. A small permanently lubricated and sealed electric motor is coupled to the rotor-type washer pump. A seal flange with a barbed inlet nipple (6) on the pump housing passes through a rubber grommet seal installed in a dedicated mounting hole of the washer reservoir. A removable molded plastic filter screen (7) inserted into the inlet nipple prevents most debris from entering the pump housing. When the pump is installed in the reservoir a barbed outlet nipple (5) on the pump housing connects the unit to the washer system through a short washer reservoir hose. The washer pump/motor unit is retained on the reservoir by the interference fit between the barbed pump inlet nipple and the grommet seal, which is a light press fit. The top of the washer pump is also secured to the washer reservoir by the use of a snap post (2) on the motor housing and a snap post receptacle molded into the reservoir that allows for mounting of the washer pump without the use of fasteners. An integral connector receptacle (3) on the top of the motor housing connects the unit to the vehicle electrical system. The washer pump/motor unit cannot be repaired. If ineffective or damaged, the entire washer pump/motor unit must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Description and Operation > Description > Page 17174 Windshield Washer Pump: Description and Operation Operation OPERATION The washer pump/motor unit features a small Direct Current (DC) electric motor. The motor is connected to the vehicle electrical system through a single take out and two-cavity connector of the right (gasoline engines) or left (diesel engines) headlamp and dash wire harness. The motor is grounded at all times through another take out of the right (gasoline engines) or left (diesel engines) headlamp and dash wire harness. On vehicles with a gasoline engine, a single eyelet terminal connector is secured by a nut to a ground stud located on the right front fender inner shield in the engine compartment. On vehicles with a diesel engine, an eyelet terminal connector is secured by a ground screw to the left front fender inner shield in the engine compartment. The motor receives battery current on a washer pump/motor control circuit. The washer pump/motor control circuit is energized through a high side driver within the Totally Integrated Power Module (TIPM) whenever the TIPM receives an electronic message requesting washer system operation from the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) over the Controller Area Network (CAN) data bus. The EMIC monitors a resistor multiplexed hard wired input from the momentary washer switch contacts within the multi-function switch on the steering column to determine when it should issue the electronic message requesting washer system operation. Washer fluid is gravity-fed from the washer reservoir to the inlet side of the washer pump. When the pump motor is energized, the motor spins the rotor within the washer pump. The spinning pump rotor pressurizes the washer fluid and forces it through the pump outlet nipple, the washer plumbing, and the washer nozzles onto the windshield glass. The washer pump/motor unit and the hard wired motor control circuits from the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the washer pump/motor unit or the electronic controls or communication between other modules and devices that provide some features of the wiper and washer system. The most reliable, efficient, and accurate means to diagnose the washer pump/motor unit or the electronic controls and communication related to washer pump/motor unit operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Removal Windshield Washer Pump: Service and Repair Removal DIESEL ENGINE NOTE: The washer pump/motor unit can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the washer hose from the barbed outlet nipple (8) of the washer pump/motor unit and allow the washer fluid to drain into a clean container for reuse. 3. Disconnect the left headlamp and dash wire harness connector from the washer pump/motor unit connector receptacle (1). 4. Firmly grasp the top of the washer pump/motor housing. 5. Pull lightly outward on the top of the washer pump/motor housing, away from the washer reservoir (6) far enough to disengage the snap post (2) on the top of the motor from the receptacle (3) in the reservoir. 6. Pull the washer pump/motor unit straight out from the washer reservoir far enough to disengage the barbed pump inlet nipple (7) from the rubber grommet seal (4) in the reservoir. 7. Remove the washer pump/motor unit from behind the washer reservoir. 8. Remove the rubber grommet seal from the pump mounting hole in the reservoir and discard. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Removal > Page 17177 Windshield Washer Pump: Service and Repair Installation DIESEL ENGINE 1. Install a new rubber grommet seal (4) into the washer pump mounting hole in the washer reservoir (6). Always use a new rubber grommet seal on the reservoir. 2. Position the barbed inlet nipple (7) of the washer pump to the rubber grommet seal in the reservoir. 3. Using hand pressure, press firmly and evenly on the washer pump/motor unit until the barbed inlet nipple is fully seated in the rubber grommet seal in the pump mounting hole of the reservoir. 4. Align the snap post (2) on the top of the pump motor housing with the snap post receptacle (3) in the washer reservoir. 5. Using hand pressure, press firmly and evenly on the top of washer pump/motor unit until the snap post snaps into the receptacle. 6. Reconnect the washer reservoir hose to the barbed pump outlet nipple (8). 7. Reconnect the left headlamp and dash wire harness connector to the washer pump/motor unit connector receptacle (1). 8. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 9. Reconnect the battery negative cable. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Description and Operation > Description Windshield Washer Reservoir: Description and Operation Description DESCRIPTION Except on 5.9L diesel vehicles, the molded plastic washer fluid reservoir (1) is integral to the engine coolant overflow bottle. On gas vehicles, the reservoir (4) is located on the right rearward facing surface of the engine cooling module shroud in the right front corner of the engine compartment. On 5.9L diesel vehicles, the molded plastic washer fluid reservoir is separate from the engine coolant overflow bottle and is mounted on the rearward facing surface of the left vertical member of the radiator support in the engine compartment. On 6.7L diesel, the molded plastic washer fluid reservoir is again integral to the engine coolant overflow bottle and is mounted on the rearward facing surface of the left vertical member of the radiator support in the engine compartment. These reservoirs are constructed of a translucent plastic that allows the fluid level to be inspected without removing the reservoir caps. A bright yellow plastic filler cap (2) with a rubber seal snaps over the open end of the washer reservoir filler neck and can be easily distinguished from the coolant overflow bottle cap (3) by an International Control and Display Symbol icon for Windshield Washer and the text WASHER FLUID ONLY molded into it. The cap hinges on and is secured to a molded-in hook formation on the top of the reservoir just behind the filler neck when it is removed for inspecting or adjusting the fluid level in the reservoir. Except on diesel vehicles, the washer reservoir is secured to the cooling module radiator shroud with two integral tabs at the bottom, and through two integral mounting brackets with two screws at the top. The two bottom tabs are inserted into two slots near the bottom of the shroud, while the two screws secure the mounting brackets to integral mounting points near the top of the shroud. On diesel vehicles, the washer reservoir is secured through an integral post formation at the bottom into a bracket at the base of the left vertical member of the radiator support and with two screws through integral mounting brackets to the front end structure. There are separate, dedicated holes on the lower end of each reservoir provided for the mounting of the washer/pump motor unit (6) and the washer fluid level switch (5). An integral molded receptacle for the washer pump and a routing trough for the washer hose are molded into each reservoir to allow for mounting of the washer pump/motor unit without the use of fasteners. Except on 5.9L diesel vehicles, the washer reservoir is serviced only as a unit with the engine coolant reserve bottle. A washer reservoir cannot be repaired and, if ineffective or damaged, the unit must be replaced. The washer pump/motor unit, the washer fluid level switch, their rubber grommet seals, as well as the reservoir filler cap are each available for individual service replacement. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Description and Operation > Description > Page 17182 Windshield Washer Reservoir: Description and Operation Operation OPERATION The washer fluid reservoir provides a secure, on-vehicle storage location for a large reserve of washer fluid for operation of the washer system. The washer reservoir filler neck provides a clearly marked and readily accessible point from which to add washer fluid to the reservoir. The washer/pump motor unit is located in a sump area near the bottom of the reservoir to be certain that washer fluid will be available to the pump as the fluid level in the reservoir becomes depleted. The washer fluid level switch is mounted just above the washer pump inlet nipple in the sump area of the reservoir so that there will be adequate warning to the vehicle operator that the washer fluid level is low, well before the washer system will no longer operate. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Removal Windshield Washer Reservoir: Service and Repair Removal 6.7L DIESEL ENGINE 1. Disconnect and isolate the battery negative cable. 2. Disconnect the coolant overflow hose from the nipple on the radiator filler neck. It is not necessary to open or drain the engine cooling system. 3. Disengage the reservoir washer hose from the integral routing clips on the top of the radiator fan shroud. 4. Disconnect the reservoir washer hose from the barbed nipple of the inline fitting at the engine compartment washer hose in the right headlamp and dash wire harness and allow the washer fluid to drain from the reservoir (2) into a clean container for reuse. 5. Disconnect the left headlamp and dash wire harness connector (5) from the washer fluid level switch connector receptacle (4). 6. Disconnect the left headlamp and dash wire harness connector (1) from the washer pump/motor unit connector receptacle (3). 7. Remove the two screws (2) that secure the washer reservoir (1) to the left vertical member and left lower horizontal member of the radiator support. 8. Lift the washer reservoir far enough to disengage the locator post (3) on the bottom of the coolant reserve bottle from the locator hole in the bracket (4) at the base of the left vertical member of the radiator support. 9. Remove the washer reservoir from the left side of the engine compartment. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Removal > Page 17185 Windshield Washer Reservoir: Service and Repair Installation 6.7L DIESEL ENGINE 1. Position the locator post (3) on the bottom of the coolant reserve bottle into the locator hole in the bracket (4) at the base of the left vertical member of the radiator support on the left side of the engine compartment. 2. Install and tighten the two screws (2) that secure the washer reservoir (1) to the left vertical member and left lower horizontal member of the radiator support. Tighten the screws to 10 Nm (85 in. lbs.). 3. Reconnect the left headlamp and dash wire harness (1) connector to the washer pump/motor unit connector receptacle (3). 4. Reconnect the left headlamp and dash wire harness connector (5) to the washer fluid level switch connector receptacle (4). 5. Reconnect the reservoir washer hose to the barbed nipple of the inline fitting at the engine compartment washer hose in the right headlamp and dash wire harness. 6. Engage the reservoir washer hose into the integral routing clips on the top of the radiator fan shroud. 7. Reconnect the coolant overflow hose to the nipple on the radiator filler neck. 8. Refill the washer reservoir (2) with the washer fluid drained from the reservoir during the removal procedure. 9. Reconnect the battery negative cable. 10. Check and adjust the coolant level in the coolant overflow bottle as necessary. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation > Description Windshield Washer Spray Nozzle: Description and Operation Description DESCRIPTION The fluidic washer nozzles (1) are constructed of molded plastic. Each nozzle has two integral latches (2) and an anti-rotation tab (4) that secure them in dedicated holes in the cowl plenum cover/grille panel located near the base of the windshield The domed upper surface of the washer nozzle is visible on the top of the plenum cover/grille panel, and the nozzle orifice (5) is oriented towards the windshield glass. The washer plumbing fittings (3) for the washer nozzles extend below the cowl plenum cover/grille panel. The cowl plenum cover/grille panel must be removed from the vehicle to access the nozzles for service. The washer nozzles cannot be adjusted or repaired. If ineffective or damaged, they must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation > Description > Page 17190 Windshield Washer Spray Nozzle: Description and Operation Operation OPERATION The two washer nozzles are designed to dispense washer fluid into the wiper pattern area on the outside of the windshield glass. Pressurized washer fluid is fed to each nozzle from the washer reservoir by the washer pump/motor unit through a single hose, which is attached to a barbed nipple on each washer nozzle below the cowl plenum cover/grille panel. A fluidic matrix within the washer nozzle causes the pressurized washer fluid to be emitted from the nozzle orifice as an oscillating stream to more effectively cover a larger area of the glass to be cleaned. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair > Removal Windshield Washer Spray Nozzle: Service and Repair Removal REMOVAL 1. Remove both wiper arms from the wiper pivots. 2. Unlatch and open the hood. 3. Remove the cowl plenum cover/grille panel from over the cowl plenum. 4. From the underside of the cowl plenum cover/grille panel (1), disconnect the washer nozzle hose from the barbed nipple (3) of the washer nozzle. 5. From the underside of the cowl plenum cover/grille panel, release the integral latch features (6) of the washer nozzle and push the nozzle out through the mounting hole toward the top side of the cowl plenum cover/grille panel. 6. Remove the washer nozzle from the top of the cowl plenum cover/grille panel. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair > Removal > Page 17193 Windshield Washer Spray Nozzle: Service and Repair Installation INSTALLATION 1. From the top of the cowl plenum cover/grille panel, position the nipple end of the washer nozzle through the mounting hole and engage the anti-rotation tabs (2 and 4) of the nozzle into the anti-rotation notches in the mounting hole. 2. Using hand pressure, push firmly and evenly on the top of the washer nozzle until the integral latch features (6) lock into place on the underside of the cowl plenum cover/grille panel (1). 3. From the underside of the cowl plenum cover/grille panel, reconnect the washer hose to the barbed nipple (3) of the washer nozzle. 4. Reinstall the washer nozzle hose into its routing clips on the underside of the cowl plenum cover/grille panel. 5. Reinstall the cowl plenum cover/grille panel over the cowl plenum. 6. Close and latch the hood. 7. Reinstall both wiper arms onto the wiper pivots. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Description and Operation > Description Wiper Arm: Description and Operation Description DESCRIPTION The wiper arms are the rigid members located between the wiper pivots protruding from the cowl plenum cover/grille panel near the base of the windshield and the wiper blades on the windshield glass. Both wiper arms feature an over-center hinge that allows easy access to the windshield glass for cleaning. The wiper arms each have a die cast metal pivot end (3) with a large internally serrated socket formation at one end. A key (4) within the socket formation indexes the wiper arm to a keyway in the pivot shaft to provide wiper alignment, and a spring-loaded latch (5) on the underside of the pivot end locks the unit to the pivot shaft when it is fully installed. The wide end of a tapered, stamped steel channel (8) hinges on and is secured with a hinge pin (6) to the blade end of both the right and left wiper arm pivot ends. One end of a long, rigid, stamped steel strap (2), with a small hole near its pivot end, is riveted and crimped within the narrow end of the stamped steel channel. The tip of the wiper blade end of this strap is bent back under itself to form a small hook (1). Concealed within the stamped steel channel, one end of a long spring (7) is engaged with a wire hook on the underside of the die cast pivot end, while the other end of the spring is hooked through the small hole in the steel strap. The entire wiper arm has a satin black finish applied to all of its visible surfaces. The right and left wiper arms are unique and are not interchangeable. A wiper arm cannot be adjusted or repaired. If damaged or ineffective, the entire wiper arm unit must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Description and Operation > Description > Page 17198 Wiper Arm: Description and Operation Operation OPERATION The wiper arms are designed to mechanically transmit the motion from the wiper pivots to the wiper blades. The wiper arm must be properly indexed to the wiper pivot in order to maintain the proper wiper blade travel on the glass. The serrated and keyed socket formation in the wiper arm pivot end interlocks with the serrations and keyway on the outer circumference of the wiper pivot shaft, providing positive engagement and alignment of this connection. The latch positively locks the wiper arm to the wiper pivot shaft when the arm is fully installed. The spring-loaded wiper arm hinge controls the down-force applied through the tip of the wiper arm to the wiper blade on the glass. The hook formation on the tip of the wiper arm provides a cradle for securing and latching the wiper blade pivot block to the wiper arm. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Removal Wiper Arm: Service and Repair Removal REMOVAL 1. Lift the wiper arm to its over-center position to hold the wiper blade off of the glass and relieve the spring tension on the wiper arm to wiper pivot shaft connection. 2. Pull the latch (2) on the pivot end (1) of the wiper arm outward. 3. Using a slight rocking action, disengage and remove the wiper arm pivot end from the wiper pivot shaft. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Removal > Page 17201 Wiper Arm: Service and Repair Installation INSTALLATION NOTE: The right and left wiper arms are not interchangeable. The right wiper arm is slightly longer than the left. Be certain that each wiper arm is installed on the proper wiper pivot. 1. Place the wiper arm hinge in its over-center position prior to attempting installation. 2. The wiper arms are indexed to the wiper pivot shafts with integral keys in the wiper arm pivot ends (1) and keyways in the wiper pivot shafts. Align the key of the wiper arm to the keyway on the wiper pivot shaft. 3. Once the wiper blade is aligned, push the pivot end of the wiper arm down firmly and evenly over the wiper pivot shaft until it is fully engaged. When the wiper arm is fully engaged on the wiper pivot, the spring-loaded latch (2) will snap back into place against the wiper arm pivot end. 4. Gently lower the wiper arm until the wiper blade is in position on the windshield glass. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Description and Operation > Description Wiper Blade: Description and Operation Description DESCRIPTION Each wiper blade is secured by an integral latching pivot block (3) to the hook formation on the tip of each wiper arm, and rests on the glass near the base of the windshield when the wipers are not in operation. The wiper blade consists of the following components: - Superstructure (1) - The superstructure includes several stamped steel bridges and links with claw formations that grip the wiper blade element. Also included in this unit is the latching, molded plastic pivot block that secures the superstructure to the wiper arm. All of the metal components of the wiper blade have a satin black finish applied. - Element (2) - The wiper element or squeegee is the resilient rubber member of the wiper blade that contacts the glass. - Flexor (7) - The flexor is a rigid metal component running along the length of each side of the wiper element where it is gripped by the claws (6) of the superstructure. The right and left wiper blades are 60.00 centimeters (23.62 inches) long, and are interchangeable. They have non-replaceable rubber elements (squeegees). The wiper blades cannot be adjusted or repaired. If ineffective, worn, or damaged the entire wiper blade unit must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Description and Operation > Description > Page 17206 Wiper Blade: Description and Operation Operation OPERATION The wiper blades are moved back and forth across the glass by the wiper arms when the wipers are being operated. The wiper blade superstructure is the flexible frame that grips the wiper blade element and evenly distributes the force of the spring-loaded wiper arm along the length of the element. The combination of the wiper arm force and the flexibility of the superstructure makes the element conform to and maintain proper contact with the glass, even as the blade is moved over the varied curvature that may be encountered across the glass surface. The wiper element flexor provides the claws of the blade superstructure with a rigid, yet flexible component on the element which can be gripped. The rubber element is designed to be stiff enough to maintain an even cleaning edge as it is drawn across the glass, yet resilient enough to conform to the glass surface and flip from one cleaning edge to the other each time the wiper blade changes directions. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Removal Wiper Blade: Service and Repair Removal REMOVAL CAUTION: Do not allow the wiper arm to spring back against the glass without the wiper blade in place or the glass may be damaged. NOTE: The notched end of the wiper element flexor should always be oriented towards the end of the wiper blade that is nearest to the wiper pivot. 1. Lift the wiper arm (2) to raise the wiper blade and element (6) off of the glass, until the wiper arm hinge is in its over-center position. 2. To remove the blade from the arm, depress the latch release tab (4) on the pivot block (3) under the tip of the arm downward (toward the wiper element and away from the wiper arm) and slide the blade away from the tip towards the pivot end of the arm far enough to disengage the pivot block from the hook formation (5) on the end of the arm. 3. Extract the hook formation on the tip of the wiper arm through the opening in the wiper blade superstructure (1) just ahead of the pivot block. 4. Gently lower the tip of the wiper arm onto the glass. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Removal > Page 17209 Wiper Blade: Service and Repair Installation INSTALLATION CAUTION: Do not allow the wiper arm to spring back against the glass without the wiper blade in place or the glass may be damaged. NOTE: The notched end of the wiper element flexor should always be oriented towards the end of the wiper blade that is nearest to the wiper pivot. 1. Lift the wiper arm (2) off of the windshield glass, until the wiper arm hinge is in its over-center position. 2. Position the wiper blade near the hook formation (5) on the tip of the arm with the notched end of the wiper element flexor oriented towards the end of the wiper arm that is nearest to the wiper pivot. 3. Insert the hook formation on the tip of the arm through the opening in the blade superstructure (1) ahead of the pivot block (3) far enough to engage the pivot block into the hook. 4. Slide the pivot block up into the hook formation on the tip of the wiper arm until the latch release tab (4) snaps into its locked position. Latch engagement will be accompanied by an audible click. 5. Gently lower the wiper blade and element (6) onto the glass. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement Technical Service Bulletin # J11 Date: 090821 Recall - Windshield Wiper Motor Replacement August 2009 Dealer Service Instructions for: Safety Recall J11 Mopar Windshield Wiper Motor Models 2002-2008 (DR) Dodge Truck (1500 series pickup) 2005-2009 (DH) Dodge Truck (2500 series pickup) 2006-2009 (D1) Dodge Truck (3500 series pickup) 2007-2008 (DC) Dodge Truck (3500 series cab chassis) 2008 (DM) Dodge Truck (4500/5500 series cab chassis) NOTE: This recall applies only to the above vehicles that had the original windshield wiper motor replaced with a Mopar service parts windshield wiper motor. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject During a prior service appointment, a Mopar service parts windshield wiper motor may have been installed on about 1,000 of the above vehicles. These replacement wiper motors may fail under certain operating conditions. A loss of windshield wipers could limit the driver's visibility and cause a crash without warning. Repair The windshield wiper motor must be inspected. Vehicles equipped with a Mopar service parts windshield wiper motor must have the motor replaced. Parts Information Special Tools No special tools are required to perform this service procedure. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 17218 Use the labor operation number and time allowance shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure 1. Remove the right and left wiper arms from the wiper pivots. 2. Open the hood. 3. Disconnect and isolate the negative battery cable(s). 4. Remove the plenum cover sound deadening pad. 5. Remove the plastic cowl plenum cover panel from the cowl plenum to expose the wiper motor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 17219 6. Inspect the windshield wiper motor: > If the wiper motor has two rubber mounting bushings (Figure 1), the wiper motor is original and is not involved in this recall. Continue with Step 21 of this procedure. NOTE: If the original wiper motor requires some type of repair, the repair cost is the responsibility of the vehicle owner. > If the windshield wiper motor has one rubber mounting bushing (Figure 2), the wiper motor is a Mopar replacement motor and is involved in this recall. Continue with Step 7 of this procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 17220 7. Disconnect the wiper motor electrical connector (Figure 3). 8. Remove the wiper motor linkage arm retaining nut from the wiper motor shaft (Figure 3). 9. Remove the wiper motor linkage arm from the motor shaft. NOTE: Do not disconnect the wiper motor linkage arm from the remaining wiper linkage. 10. Remove the three wiper motor retaining bolts (Figure 4). 11. Remove the wiper motor from the vehicle. 12. Transfer the rubber isolator from the old wiper motor onto the new wiper motor (Figure 4). 13. Discard the old wiper motor. 14. Place the new wiper motor into position. 15. Install the three wiper motor retaining bolts (Figure 4). 16. Tighten the upper wiper motor retaining bolts to 70 in. lbs. (8 N.m). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 17221 17. Tighten the lower mounting bolt to 75 in. lbs. (8.5 N.m). 18. Connect the wiper motor electrical connector (Figure 3). 19. Install the wiper motor linkage arm to the wiper motor shaft as shown in Figure 5. NOTE: The arms for the wiper pivots must be pointing downward (forward). 20. Install the wiper motor linkage arm nut and tighten the nut to 204 in.lbs. (23 N.m). 21. Install the plastic cowl plenum cover panel. 22. Install the plenum cover sound deadening pad. 23. Connect the negative battery cable(s) to the negative battery post(s). 24. Close the hood. 25. Install the right and left wiper arms onto the wiper pivots and verify that the wiper arm retaining clips are engaged. 26. Cycle the windshield wipers to verify proper operation and the wiper blade park position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 17222 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement Technical Service Bulletin # J11 Date: 090821 Recall - Windshield Wiper Motor Replacement August 2009 Dealer Service Instructions for: Safety Recall J11 Mopar Windshield Wiper Motor Models 2002-2008 (DR) Dodge Truck (1500 series pickup) 2005-2009 (DH) Dodge Truck (2500 series pickup) 2006-2009 (D1) Dodge Truck (3500 series pickup) 2007-2008 (DC) Dodge Truck (3500 series cab chassis) 2008 (DM) Dodge Truck (4500/5500 series cab chassis) NOTE: This recall applies only to the above vehicles that had the original windshield wiper motor replaced with a Mopar service parts windshield wiper motor. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject During a prior service appointment, a Mopar service parts windshield wiper motor may have been installed on about 1,000 of the above vehicles. These replacement wiper motors may fail under certain operating conditions. A loss of windshield wipers could limit the driver's visibility and cause a crash without warning. Repair The windshield wiper motor must be inspected. Vehicles equipped with a Mopar service parts windshield wiper motor must have the motor replaced. Parts Information Special Tools No special tools are required to perform this service procedure. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 17228 Use the labor operation number and time allowance shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure 1. Remove the right and left wiper arms from the wiper pivots. 2. Open the hood. 3. Disconnect and isolate the negative battery cable(s). 4. Remove the plenum cover sound deadening pad. 5. Remove the plastic cowl plenum cover panel from the cowl plenum to expose the wiper motor. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 17229 6. Inspect the windshield wiper motor: > If the wiper motor has two rubber mounting bushings (Figure 1), the wiper motor is original and is not involved in this recall. Continue with Step 21 of this procedure. NOTE: If the original wiper motor requires some type of repair, the repair cost is the responsibility of the vehicle owner. > If the windshield wiper motor has one rubber mounting bushing (Figure 2), the wiper motor is a Mopar replacement motor and is involved in this recall. Continue with Step 7 of this procedure. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 17230 7. Disconnect the wiper motor electrical connector (Figure 3). 8. Remove the wiper motor linkage arm retaining nut from the wiper motor shaft (Figure 3). 9. Remove the wiper motor linkage arm from the motor shaft. NOTE: Do not disconnect the wiper motor linkage arm from the remaining wiper linkage. 10. Remove the three wiper motor retaining bolts (Figure 4). 11. Remove the wiper motor from the vehicle. 12. Transfer the rubber isolator from the old wiper motor onto the new wiper motor (Figure 4). 13. Discard the old wiper motor. 14. Place the new wiper motor into position. 15. Install the three wiper motor retaining bolts (Figure 4). 16. Tighten the upper wiper motor retaining bolts to 70 in. lbs. (8 N.m). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 17231 17. Tighten the lower mounting bolt to 75 in. lbs. (8.5 N.m). 18. Connect the wiper motor electrical connector (Figure 3). 19. Install the wiper motor linkage arm to the wiper motor shaft as shown in Figure 5. NOTE: The arms for the wiper pivots must be pointing downward (forward). 20. Install the wiper motor linkage arm nut and tighten the nut to 204 in.lbs. (23 N.m). 21. Install the plastic cowl plenum cover panel. 22. Install the plenum cover sound deadening pad. 23. Connect the negative battery cable(s) to the negative battery post(s). 24. Close the hood. 25. Install the right and left wiper arms onto the wiper pivots and verify that the wiper arm retaining clips are engaged. 26. Cycle the windshield wipers to verify proper operation and the wiper blade park position. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 17232 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Page 17233 Wiper Motor: Locations Component ID: 231 Component : MOTOR-WIPER-FRONT Connector: Name : MOTOR-WIPER-FRONT Color : # of pins : 4 A WIPER MOTOR HIGH SPEED FEED W4 12BR/OR B WIPER LOW SPEED CONTROL OUTPUT W3 18BR/WT C GROUND Z103 12BK/WT D WIPER PARK SWITCH SENSE W7 20BR/GY Component Location - 32 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Page 17234 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Page 17235 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions Wiper Motor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 17238 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 17239 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 17240 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic Transmissions-Front Wheel Drive Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 17241 MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC -Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North America Except Export -Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 17242 Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 17243 IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 17244 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 17245 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 17246 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 17247 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 17248 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 17249 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 17250 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 17251 Wiper Motor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 17252 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 17253 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 17254 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 17255 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 17256 Wiper Motor: Connector Views Component ID: 231 Component : MOTOR-WIPER-FRONT Connector: Name : MOTOR-WIPER-FRONT Color : # of pins : 4 A WIPER MOTOR HIGH SPEED FEED W4 12BR/OR B WIPER LOW SPEED CONTROL OUTPUT W3 18BR/WT C GROUND Z103 12BK/WT D WIPER PARK SWITCH SENSE W7 20BR/GY Component Location - 32 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 17257 Component Location - 30 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 17258 Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Description and Operation > Description Wiper Motor: Description and Operation Description DESCRIPTION The wiper module is secured with screws through three rubber grommet-type insulators (5) to the cowl plenum panel. The module is concealed beneath the molded plastic cowl plenum cover/grille panel between the base of the windshield and the rear edge of the hood panel. The ends of the pivot shafts protruding through openings in the cowl plenum cover/grille panel to drive the wiper arms and blades are the only visible components of the wiper module. The wiper module consists of the following major components: - Bracket - The wiper module bracket consists of a long tubular steel main member (2) that has a die cast pivot bracket (1) at each end to which the two wiper pivots are secured. A stamped steel clamp secures the center of the tubular member to the die cast bracket integral to the wiper motor with two screws. Crank Arm (10) - The wiper motor crank arm is a stamped steel unit with a slotted hole on the driven end that is secured to the wiper motor output shaft with a nut, and has a long ball stud secured to the drive end to accept the wiper linkage. - Linkage (2) - Two tubular steel drive links connect the wiper motor crank arm to the wiper pivot lever arms. The left side drive link has a plastic socket-type bushing (6) on each end. The right side drive link has a plastic socket-type bushing on one end, and a plastic sleeve-type bushing on the other end. The socket-type bushing on one end of each drive link is snap-fit over the ball stud on the lever arm (8) of its respective pivot. The right side drive link sleeve-type bushing end is then fit over the motor crank arm ball stud, and the other socket-type bushing of the left side drive link is snap-fit over the exposed end of the wiper motor crank arm ball stud. - Motor (11) - The wiper motor features an integral die cast bracket to which the wiper module bracket is secured with a stamped steel clamp and two screws near the top and which has a single rubber insulated mounting ear at the bottom. This die casting also serves as the wiper motor transmission housing from which the wiper motor output shaft exits. A nut secures the wiper motor crank arm to the motor output shaft. The two-speed permanent magnet wiper motor features an integral transmission, an internal park switch, and an internal automatic resetting circuit breaker. A short pigtail wire and connector connect the wiper motor to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. Pivots (2) - The two wiper pivots are secured within the die cast pivot brackets on the outboard ends of the wiper module main member. The lever arms that extend from the center of the pivot shafts each have a ball stud on their end. The upper end of each pivot shaft where the wiper arms will be fastened each has a serrated driver with a keyway. The lower ends of the pivot shafts are installed through lubricated bushings in the pivot brackets and are secured with snap rings. The wiper module cannot be adjusted or repaired. If any component of the module is ineffective or damaged, the entire wiper module unit must be replaced. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Description and Operation > Description > Page 17261 Wiper Motor: Description and Operation Operation OPERATION The wiper module operation is controlled by the battery current inputs received by the wiper motor from the Totally Integrated Power Module (TIPM). The wiper motor speed is controlled by current flow to either the low speed or the high speed set of brushes. The park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately opens and closes the wiper park switch sense circuit to ground, depending upon the position of the wipers on the glass. This feature allows the motor to complete its current wipe cycle after the wiper system has been turned OFF, and to park the wiper blades in the lowest portion of the wipe pattern. The automatic resetting circuit breaker protects the motor from overloads. The wiper motor crank arm, the two wiper linkage members, and the two driven wiper pivots mechanically convert the rotary output of the wiper motor to the back and forth wiping motion of the wiper arms and blades on the glass. The hard wired inputs and outputs of the front wiper motor may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the wiper motor or the electronic controls or communication between other modules and devices that provide some features of the wiper and washer system. The most reliable, efficient, and accurate means to diagnose the wiper motor or the electronic controls and communication related to wiper motor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Removal Wiper Motor: Service and Repair Removal REMOVAL 1. Remove both wiper arms (4) from the wiper pivots. 2. Unlatch and open the hood. 3. Disconnect and isolate the battery negative cable. 4. Remove the cowl plenum cover/grille panel (5) from over the cowl plenum (8). 5. Disconnect the left headlamp and dash wire harness connector (7) from the wiper motor pigtail wire connector. 6. Remove the two screws (9) that secure the wiper module (6) to the top of the cowl plenum panel at the pivot brackets. 7. Remove the screw that secures the wiper module to the bottom of the cowl plenum panel. 8. Remove the wiper module from the cowl plenum panel as a unit. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Removal > Page 17264 Wiper Motor: Service and Repair Installation INSTALLATION 1. Position the wiper module (6) into the cowl plenum (8) as a unit. 2. Install the two screws (9) that secure the wiper module to the top of the cowl plenum panel at the pivot brackets. Tighten the screw on the driver side, followed by the screw on the passenger side. Tighten the screws to 8 Nm (75 in. lbs.). 3. Install and tighten the screw that secures the wiper module to the bottom of the cowl plenum panel. Tighten the screw to 8 Nm (75 in. lbs.). 4. Reconnect the left headlamp and dash wire harness connector (7) to the wiper motor pigtail wire connector. 5. Reinstall the cowl plenum cover/grille panel (5) over the cowl plenum. 6. Reconnect the battery negative cable. 7. Close and latch the hood. 8. Reinstall both wiper arms (4) onto the wiper pivots. Dodge Ram 3500 Hd 4wd Workshop Manual (Truck L6-6.7L DSL Turbo VIN A (2007)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Dodge Ram 2006-2008, 1500-5500 all, do not use a wiper relay.